Dubz Posted June 19, 2014 Share Posted June 19, 2014 Hello thanks for looking and please try to read the whole thing. I have a 2005 2.5i with the big single ported manifolds that go to the dreaded long equal length headers with 3 cats and 5 o2 sensors I put oem legacy gt headers on them and had someone fabricate them to the rest of the exhaust. Putting the dual port headers on a single port heads wouldn't mean it exactly lines up and the stock gaskets would leave a gap so I put on dual port gaskets on with a big hole cut in the middle. The thing is cutting the dual ported gaskets weakened themand now I have a huge leak from the gaskets. I thought of welding my stock flanges on them so I took it to the guy who did this all to see if hell CNC flanges and that would be $200 and he said he wants to redo the whole thing his way with the flanges but it will be another 1000 if it has his name on it. I'm already in these headers over 600 from this guy and spending it on a 2.5i for a rumble is rediculous. also the headers are cast iron so nobody would be able to weld to it so I've been told Long story short. I think I only have 2 options since the only problem with the leak is in the gaskets. So either A) put an adapter in using the stock gasket but more like how I drew it out pictured below, or B) throw everything away and go back to stock:((((( I saw ONE person do this with lgt headers on a different forum but can't find the link so I was almost certain it could be done. So I'm looking to see if any local places could do it cheaper cuz it doesn't seem that hard to make a flange. Or will someone on here reading this think they can make something kinda in the picture but better? http://img.tapatalk.com/d/14/06/19/ze3ygy2e.jpg http://img.tapatalk.com/d/14/06/19/pu3aqu7e.jpg http://img.tapatalk.com/d/14/06/19/ugy9uduh.jpg These are what the dual ported gaskets are shaped like:http://img.tapatalk.com/d/14/06/19/4umu6ypa.jpg And these are what my stock gaskets are shaped like so something had to be made that fits both of these kinda how I drewhttp://img.tapatalk.com/d/14/06/19/neqe9equ.jpg Sent from my iPhone using Tapatalk Link to comment Share on other sites More sharing options...
spec.B452 Posted June 19, 2014 Share Posted June 19, 2014 Gobs of super high temp copper rtv gasket sealant? Link to comment Share on other sites More sharing options...
Dubz Posted June 19, 2014 Author Share Posted June 19, 2014 Do you think that'll work? The gasket in the 3rd pic would seem like id need layers and layers if that'll even do it. A guy I know tried it and it stopped it for only 6 months Sent from my iPhone using Tapatalk Link to comment Share on other sites More sharing options...
spec.B452 Posted June 19, 2014 Share Posted June 19, 2014 I don't know if it would hold up but it would be the cheapest way to go as long as you give it adequate curing time. You could also try stacking gaskets to fill the gap. The copper worked for me on a non turbo car (1971 240z). No idea.on how it would work o n a modern car with turbo backpressure. Link to comment Share on other sites More sharing options...
Dubz Posted June 19, 2014 Author Share Posted June 19, 2014 It's a 2.5i no turbo. Yeah I'll try it everyone tells me double stacking gaskets and sealant would make it worse but never tried it myself Sent from my iPhone using Tapatalk Link to comment Share on other sites More sharing options...
spec.B452 Posted June 19, 2014 Share Posted June 19, 2014 Yeah, I would do 9th thing at a time to minimize variables. If you are n/a and just look8ng.for sound you may just want stock headers and then just concentrate on. An exhaust system instead. Link to comment Share on other sites More sharing options...
JmP6889928 Posted June 19, 2014 Share Posted June 19, 2014 Have someone adapt the flanges on the exhaust manifold by adding metal and then remachining OR you could purchase a LGT header from an aftermarket company and then cut off the flange and reweld on a new one that fits your heads. Link to comment Share on other sites More sharing options...
Dubz Posted June 19, 2014 Author Share Posted June 19, 2014 To be clear I searched everywhere to find Uel headers that fit my setup and there isn't any. Even if there was there wouldn't be a big enough market for one. The reason I chose the lgt headers was that they have dual ports going into a thicker pipe. Rather than just having 2 skinny pipes going the whole way so I wouldn't be able to adapt to that at all. The lgt headers could have metal added if they are easily weldable Sent from my iPhone using Tapatalk Link to comment Share on other sites More sharing options...
Max Capacity Posted June 19, 2014 Share Posted June 19, 2014 Just leave the divider in the gasket. 305,600miles 5/2012 ej257 short block, 8/2011 installed VF52 turbo, @20.8psi, 280whp, 300ftlbs. (SOLD). CHECK your oil, these cars use it. Engine Build - Click Here Link to comment Share on other sites More sharing options...
Dubz Posted June 19, 2014 Author Share Posted June 19, 2014 I'll try all of these at once and see if it works? Lol Sent from my iPhone using Tapatalk Link to comment Share on other sites More sharing options...
Free Range Racing Posted June 20, 2014 Share Posted June 20, 2014 you just need to fabricate an adapter plate. Should be able to do it with reasonable hand tools and some scrap sheet metal. Link to comment Share on other sites More sharing options...
Dubz Posted June 21, 2014 Author Share Posted June 21, 2014 Sheet metal? No plates? Sent from my iPhone using Tapatalk Link to comment Share on other sites More sharing options...
Free Range Racing Posted June 21, 2014 Share Posted June 21, 2014 yeah a piece of 1/8" steel cut like you've got the gasket that failed cut, the gasket it on both sides. If you don't have a good source of steel try ebay, it's amazing what you can get sent to your door for $10 Link to comment Share on other sites More sharing options...
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