New SSI Heat Exchanger Muffler Flanges not flat.

Just a note to all considering SSI heat exchangers - I noticed when I bought the SSI's that the muffler flanges appeared to be a little uneven. I had heard nothing but good things about the quality of SSI's so I figured they must know something I don't. Well, sure enough, the exhaust leaked at the flanges. I'm not sure whether I should send them back or just go to a local machine shop and have them "Decked". I enjoyed the few times I got to drive the car with them installed but the popping on overrun told me the exhaust leak needed attention. If you buy a pair I suggest a careful inspection upon receipt.

Happy Motoring to All.

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Eric Purdy - 1980
911SC

Eric,

You can correct this. I noticed this on mine too before I put them in. You can even them out by just pulling up/pushing down on them until they are even with a straight edge (ie one foot on the box, pull/push on the flange with both hands). The header pipes are not welded to the boxes, but rather are just pressed up against the pipes. They will slide in either direction about 1-2cm. I think mine got battered in shipping. Gave me a moment of pause, then I realized this tidbit.

Nick.

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Nick Shumaker
1982 911SC Coupe
nickshu@yahoo.com
PCA -- Rocky Mtn. Region

if you lube the exhaust studs you may be able to tighten the nuts more. some exhaust gaskets don't have much of a "crush", so they won't take up slight irregularities.

Nickshu,
Actually it's the flanges that connect to the muffler itself that are warped - so to speak. I can't get a good seal at the center of the flange since the two ends near the bolts are higher.

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Eric Purdy - 1980
911SC

Call the SSI people and ask them what they would like to do for you? Bad press on this BB is not a good thing.
I'm sure they'll be more than willing to help you adjust the anomalies.
Mrdi

Mrdi,
That is what I intend to do. The boxes they came in have no phone number - anyone have one? Otherwise I'll just track it down.


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Eric Purdy - 1980
911SC

Try: 415-883-2000 0r 800-227-1486

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Doug
'81 SC Coupe (aka: "Blue Bomber")
Canada West Region PCA
members.home.net/zielke/911SC.htm

Thanks Doug.

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Eric Purdy - 1980
911SC

Eric,please let us know what SSI's response to your problem is.

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Doug
'81 SC Coupe (aka: "Blue Bomber")
Canada West Region PCA
members.home.net/zielke/911SC.htm

Will do.

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Eric Purdy - 1980
911SC

Oh. Sorry I misunderstood what you were describing. Sounds like your problem is less easily fixed. As said above, I would call SSI.

Nick.

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Nick Shumaker
1982 911SC Coupe
nickshu@yahoo.com
PCA -- Rocky Mtn. Region

I talked to SSI this AM. Very nice folks who were genuinely interested in my problem. I am going to send the exchanger back and they will fix it or replace it ASAP. FYI, the flanges are not flat as they come from the factory. They are higher in the center where the gasket seals. As you torque the bolts down, the outer part of the flanges are pulled down to meet the center. For some reason mine didn't seal and SSI is very interested in why. Thanks to all who offered suggestions. Hopefully all systems will be go again soon.


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Eric Purdy - 1980
911SC

Just an update for all on the status. I got the SSI's back yesterday and promptly bolted them up. SSI had the heat exchanger back to me in less than a week, however they just sent it back with no note or anything. It looked as though some machine work had been done on the flange in question but it still looked uneven to me. The second thing I noticed once the heat exchanger was bolted up is that the flanges were no longer spaced the same distance as my muffler. I had to "Squeeze" the SSI header tubes towards each other in order to install the muffler. It wasn't this way before I send it back for repair. I managed to get it all installed and torqued to spec and sure enough the flange is still leaky although to a lesser extent now. I can no longer insert a feeler past the gasket but I can see water leaking out the bottom of the flange when I start the car cold. My next step is to try some copper high temp RTV. I'm wondering if I'm just running into the inherent problems sealing a two bolt flange. After all, there is a reason Porsche went to 3 bolts later on. I guess I'll keep trying. I suppose if I still can't get a good seal I'll send them back and start shopping for a different set of headers.
Has anyone else had any problems getting a good seal with a two bolt flange?

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Eric Purdy - 1980
911SC

Eric,

Are you using the OEM 901.111.193.00 gasket (still available from Stoddard's -- $3.95 each) or something else?

The reason the later flanges are 3-bolt is because it is a larger tube. The old heat exchangers NEVER had any leaking problems at those flanges, unless caused by FOD (foreign object damage) such as hitting curbs, speed bumps, off-road excursions, etc.

I am beginning to think Jet-Hot coating on my old, pitted HEs might be better than SSIs! Sandblasting and Sperex VHT is getting to be too much of a bi-annual chore!

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Warren Hall
1973 911S Targa

Warren,
Thanks - I figured I was grasping at straws with that one! Since these are all new there's no FOD damage (Familiar with jet engines?). I'm going to give the sealant a try and then make a decision from there.



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Eric Purdy - 1980
911SC