[SEL] OT - Custom headers leaking

[Best, George]

Since the list gets quiet during the Portland show I thought I'd post something for those stuck at home like myself;-)

This isn't totally off topic as it does deal with an engine, but just a different type of engine than most of you deal with.

My 64 Falcon has a custom set of Dawson Racing headers and I recently noticed some bad leaks at the slip joints for #3 and #4 cylinders on the passenger side.

In the past I've had other vehicles with headers, but they were always one piece headers made at a header factory.  This is the first time I've had something that was truly custom fabricated just for my car and engine combo.  Also the first time I've had headers that needed slip joints to be installed.

FYI.... These headers were already on the car when I bought it and unfortunately Tom Dawson died in 2009 so I believe Dawson Racing Headers died at the same time.

After reading on the internet it seems that some people have good luck sealing the slip joints with high copper content RTV silicone.  Which is what I'm planning on trying.

First thing I discovered last night is I couldn't get a socket on any of the header flange bolts, and could only get a box end wrench on one of the bolts.  Luckily and open end wrench was sufficient to undo the others although movement was very limited.  I'll probably check a tool store and see if a thin-wall socket will work.  Also considered modifying a box-end wrench by heating it up and bending it some, plus grinding off excess metal around the box-end.  Maybe a modified wrench is what I need.

I did get the #3 slip joint tube removed easy enough, but the #4 tube is still in place as I need to also remove the valve cover so the slip tube can slip up past the exhaust port.  The cast valve covers are larger than most and the extra overhang is just enough to keep the #4 slip tube from sliding up far enough to separate from the rest of the header pipe.

So.... have any of you experience with slip joint connections on header pipes?

George






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