exhaust leak...again =(

[blackbird225]

I replaced the exhaust studs, nuts and gaskets this week on my 70T. The problem is the #1 header-to-head is leaking.
I took the headers back off, razorbladed the head to make sure no debris is in the way then I noticed that the flanges were concave. I searched some posts and saw a few guys tried to have a shop "deck" the flanges, while others doubled up on gaskets.

I just want to know what the board, as a majority, would do.

I hope some of you have fun with your cars and are not simply miserable like I always am...

michael

[Wil Ferch]

Are the flanges on the header the problem? ( and not the mating flange area on the head?). If so, is there a problem in getting the header flanges flat and plane? ( other than the PITA to remove them)?

Maybe you can use a soft "yellow" metal ( copper, brass) sheet to help fill in the distortions ...as a gasket?

--Wil

[blackbird225]

That one flange is slightly concave. You can see it if you just look carefully. Also you can see where the gasses are escaping either side through the middle. I think I am going to try a flat file tomorrow. If I can "plane" it down a little...

Thanks for the reply,

thinking about selling my car after this. I thought Porsche wanted everyone to enjoy his cars? =)

[blackbird225]

Do you think exhaust leak(s) can affect performance? I swear that after I cleaned out my exhaust, and fixed several leaks, the car is much tighter and the throttle is cripser with maybe 10 more palpable horses. Can this be right ? I think the whole exhaust system was leaking gasses. I found multiple signs of black soot on nearly all surfaces.

[jdowty3]

Exhaust leaks can affect performance. Our engines are specifally tuned to run with a certain amount of back-pressure and, depending on the size, a leak is like running exhaust pipes which are too big.