Having gotten tired of having exhaust gaskets either failing when they fall apart, or crumbling when I have to disconnect a flange for some other reason, I decided to try something different.

 

I take a piece of aluminum foil.  trace a gasket on it.  Apply a stripe of copper RTV in the gasket area.  Lay a piece of woven fiberglass over it.  Apply RTV again.  Do this for a total of 4 layers.

 

The last layer, is RTV then aluminum foil.

 

Clamp the whole thing between a couple of 1/2" thick steel plates, with spacers to hold it at .050"

 

Let dry overnight or 2.

 

Remove clamps, cut out holes and trim.

 

So far, the pair I made for the heads to Y pipe are holding after 5) 30minute + drives.

 

Will update as needed....

 

Hopefully you took pics; otherwise take some the next time you make some. I would like to see how they come out. 

I'll be making more, after a few more runs, assuming they hold.   I'll take pics then.

I would use copper:

 

https://www.amazon.com/Copper-Sheet-Metal-12/dp/B00AKMNNX4

 

Two layers with this in-between:

 

http://www.fswerks.com/products/890100045

 

Just what I would try off the top of my head. Never done it so unsure about effectiveness. The copper would conform nicely and the wurth exhaust paste cures with exhaust heat so it would glue the layers together....maybe that would give you a .040" gasket or so which should seal up nicely.

 

GD

Does that Wurth paste set up hard, or with some give?

A little give maybe but pretty hard. It only sets up with exhaust heat though so the copper is going to form to the flanges, etc and then the paste would give it some rigidity.

 

GD

Any update on what you did or how it worked? I'll be replacing my exhaust and want to avoid the whole crumbling/falling apart shenanigans, so I'm interested.

Cheers!

So far they are still holding up.