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Old 07-22-2017, 11:47 AM   #1
HeadBanger
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Join Date: May 2014
Drives: '14 Subaru BRZ
Location: Ontario Canada
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Exclamation 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
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