HELP - My Endless Exhaust Leak
 

I need some help. I don't know what to do anymore, and this exhaust leak has me so frustrated I don't even enjoy driving anymore.

The basics
-JDL header
-stock overpipe
-Tomei titanium front pipe
-stock mid pipe
-muffler delete

As you can imagine, my exhaust is quite loud.
It's even louder with this damn exhaust leak that I just can't solve.

I installed my header this spring. Before I installed the header I knew I had a leak from the front pipe joint. The Tomei front pipe as a slip on joint with a clamp. I assume for shipping purposes.
I fixed that leak.
Fantastic!

Installed the header. The car is much louder as you'd expect. It's surprisingly quieter overall compared to stock header when just cruising around.
After a few days I head my exhaust leak come back. I decide to get some exhaust silicone to really seal that front pipe joint.
The leak goes away.
Great!

Two days later the leak comes back. I get under the car armed with my soapy-water spray bottle, and to my surprise no leak at the front pipe. But I hear a leak. I really didn't feel like taking the undershields off (coilovers, low to the ground, hard to get under it and work properly) so I sprayed at the front pipe to mid pipe joint. You would not believe the bubbles coming out of there.

I order some new hardware and a new gasket. I regret not taking a photo of the gasket because you would not believe how rusty and cruddy it looked. Slap the gasket and hardware on.
Leak is gone!
YES!!!

Two days later the leak comes back. fast forward about a month until now, it's only gotten worse. It's honestly embarrassing driving around. It's unbelievably loud. The drone in the cabin at highway speeds is so bad, that my ears were ringing after a 2 hour trip.

I work in a dealership. One of the techs said that odds are I've just tightened the spring kit too tight and it's wearing out the seal.
Ok, makes sense I guess.
He also suggested I get a couple of different gaskets that may have different size or shape to them. I really don't feel like changing this damn gasket every two weeks though. Of all the local people with after market exhausts, I've never heard of somebody having problems like this.

I really don't know what to do anymore.
Any and all help is appreciated

I would probably start at the begginging of the headers and work your way back with new gaskets. Ive seen people recommend Grimmspeed gaskets. Siruda gaskets came with my headers and had a nice crush ring in the center. I would recommend using Accosti Seal and every gasket,flange, seal ect. Here is my thread on header install you can see where I put the accousti seal. http://www.ft86club.com/forums/showthread.php?t=119961

It sounds to me like something in your exhaust system isn't lined up proper.

I have found that if you have to "force" two exhaust pieces together and relying solely on a gasket to keep the seal ...... it will usually, eventually leak.

I suggest you get your car up on a rack, remove stuff so you can get at the exhaust system, disconnect all exhaust pieces, find out where they aren't mating proper, bend them to fit together better then put the whole system back together with new gaskets.

Easy for me to say ....... right .... :D


humfrz

To build on Hum's suggestion I would look for hangers pulled over on weird angles or not connected at all. A hanger going off on an angle indicates streets on the pipes. Of course one that is not hooked up means vibration.

New gaskets at all three flanges of the header when I did the install. As well as on the over pipe to front pipe for good measure.
I do have an issue where once upon a time I stripped one of the holes in the trans where the exhaust hanger bolts up. I still have one bolt there though.
Could that really be my issue?

Other than that, I don't see how any part of the exhaust wouldn't line up properly.

Different types of metal (titanium vs. steel) heating up/cooling down/expanding/constricting at different rates/times?

Yes it could. The hanger positions are more important than some peopl think. That help keep things lined up and even though flexible they relieve stress.

OK, humfrz plan B ....... take your car to a muffler shop and ask them fix the leak.

Go across the street and have a breakfast sandwich and a cup of coffee.

Return, pay them, drive home and take a nap.

See ...... how easy that is .......??


humfrz

I've got a JDL exhaust setup too - catted UEL header, OP, ultra-quiet FP, then a perrin catback. I found that all three of the stock exhaust gaskets disintegrated into nothing within a year or so of installing the new exhaust. Like SuperTom recommended, I ended up going with Grimmspeed gaskets (Link) and they seem to be holding up really well.

Im actually recommending the Siruda gaskets as that is what I used. Grimmspeed is used by others with good results.
Here is the Siruda gasket see how the inner ring sits up this is crushed to form a seal when everything is tightened. http://www.frsport.com/Siruda-ITB230...p_1238083.html


And again Accousti seal on EVERY connection/seal if you want a airtight leak free exhaust. https://www.amazon.com/Walker-35959-.../dp/B000CQDL94 (This will not fill in a hole ect)

Oh man those Siruda's are a lot cheaper too.. well I know what I'm getting next time I guess. (I also had to use a dremel to slightly extend the bolt through-holes on the Grimmspeeds so that they would fit).

On top of what others have said, I had issues with the stock overpipe and catless header. I found that the different sized flanges made it hard to get a good seal as the area that overlapped between the two was quite small. Getting an aftermarket overpipe fixed this.

remflex.com

measure the inner diameter and buy gaskets from this website that match your diameter and then slot the bolt holes to have them fit. solves all exhaust leaks. money back guaranteed. really nice customer service too. I blew mine out since I didn't torque them properly they sent me replacement ones for free no questions.

Interesting, I've never heard of remflex before. What do you mean by slot the holes so they fit? Just open them up some horizontally so they have some extra play?