Date:         Sun, 13 Jul 2008 10:10:14 -0700
Reply-To:     Steven P Smith <kewsps@HOTMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Steven P Smith <kewsps@HOTMAIL.COM>
Subject:      Re: Stubborn Exhaust leak
Comments: To: Michael Diehr <md03@xochi.com>
In-Reply-To:  <1D931F2E-DE33-4236-8759-33AA3BF8AFBB@xochi.com>
Content-Type: text/plain; charset="Windows-1252"

You might try getting a big file at the hardware store and file the surfaces of the flanges flat. I bought new all new exhaust parts for my '84 1.9 and had to do this to get a good seal without stripping and breaking bolts.
The metal is fairly soft and it doesn't take a long time to get them flat.
Steven> Date: Sun, 13 Jul 2008 09:02:25 -0700> From: md03@XOCHI.COM> Subject: Stubborn Exhaust leak> To: vanagon@GERRY.VANAGON.COM> > 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? :)
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