[SEL] OT - Custom headers leaking

[Steve W.]

Best, George wrote:
> 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
> 

The slip joint style can be a PIA. However I have used a couple items in 
the past to seal them. One being a high temp silicone like you are 
talking about. The other was a dedicated high silica exhaust pipe 
sealant. You can buy both at most auto parts places.

As for the thin wall socket, S&K, and Snap-on both sell header sockets 
for this use OR you can get special header bolts that have a smaller 
head with an external torx or spline drive. Those allow you to tighten 
them down good and use a smaller socket.
-- 
Steve W.