Date:         Sun, 13 Jul 2008 09:02:25 -0700
Reply-To:     Michael Diehr <md03@XOCHI.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Michael Diehr <md03@XOCHI.COM>
Subject:      Stubborn Exhaust leak
Content-Type: text/plain; charset=US-ASCII; format=flowed; delsp=yes

85 vanagon with exhaust leak at the junction between the two header
pipes and the collector pipe (part #G on this picture:  http://www.bus-boys.com/vanwasser83-91.html
  )    I removed the parts, sanded off the remains of the gaskets,
installed new gaskets, bolted it back together and... it leaks just as
bad as before.   Took it apart again --   The collector pipe (G) seems
ok, but the ends of the header pipes are pretty rusted, and I can see
how it may be difficult for the gasket to seal.   Tried some high-
temperature metal gunk to fill in the gaps, then reassembled but
didn't really seem to help :(.  FYI, I put the metal side of the
gasket towards the collector as that seemed the most logical and
seemed to match the prior parts, though Bentley was not clear on that
topic.

I'm tempted to take it to my local mechanic, hat in hand, and say
"make it work!" but I haven't entirely lost faith yet.   Is the
solution new header pipes?  A MIG welder? :)