Header adaptor gasket gaps help
 

Georges euro headers and adaptors. No matter how I arrange these or order of tightening there’s always a substantial gap. They seem to bow when bolts are tightened. Any ideas? The mating surface is flat. Thicker gasket? What’s the trick?

http://forums.pelicanparts.com/uploa...1752331726.jpg
http://forums.pelicanparts.com/uploa...1752331726.jpg
http://forums.pelicanparts.com/uploa...1752331726.jpg

Maybe hammer a reverse curve into the more flexible side.

Yeah. I put the ears in a vice and bent them back a bit. Problem is the 90 degree from there. Or top and bottom is where the gaps are not the sides with the bolts. This should be crushing this gasket.

My big 12” sanding disk would work.

Yeah. I had to grind a bit to get the header side flat. Looks to be sealing now. Bit of a puzzle to get all these things to mate flat.

Yep thats what I used but 8 inch,warped flanges on my muffler ,take your time and check with a straight edge, new factory gaskets and all is good.

I would think if the ears are bending, grinding them flat would only make them thinner, and flex more.

If the flange was thicker, it wouldn’t bend (as much).

Maybe double the gasket up, but make sure you’re using a quality metal backed gasket?

I’m not to sure about doubling up the gasket. I would think it would exasperate the problem. A thicker flange would help immensely.

Taking another look, how about welding a thicker flange on the existing.

Or go to a V-Band Clamp joint.

https://www.ievilenergy.com/products/v-band-clamp-with-flange-quick-release-stainless-steel

or

https://ebay.us/m/LpRPOh

or replace the joint

https://ebay.us/m/Usznlz

or add repair doubler

https://ebay.us/m/JEBCxz

Sounds like you may have it fixed now, but I'd guess something was tweaking the header extensions and trying to bend them relative to the header flange. In the middle pic in the first post, it looks like the extension farther away from the camera is at an angle compared to the header. Sounds like the grinding you did addressed that.