Header flanges and gaskets

[elliotaw]

Sorry if this treads on anyones elses toes, I'm sure there are a few others on here in the same game as myself, so I appologise in advance...i've looked throught the most common threads on the subject on the board but not each and every thread as theres hours of info and text on this subject.....

I will be making new 304 stainless headers for my car. I deal with a local laser cutters who is unbeatable on his costs with anyone else I have asked for quotes, I have used the same company for several years and have always had fast turnaround and excellent service.

I have already done the CAD drawing for new header flanges, O.E 3 pin PCD cat flanges and the emissions flange.
I read someone else has done the same thing and the price was fairly high from what I can remember reading....

I will also possibly look into getting some copper gaskets for each made at the same time.

If anyone is interested I can post the prices I can get them made at. I do this stuff with other car parts and sell them on ebay all over the world so 'yes' I am trying to make a few quid here and there, but I am not trying to become a millionare overnight so I only add a very small percentage to cover my own costs.

Hope this helps some of you out as I know there must be quite a few others out there in the same or a similar sized boat.

Elliot

 

[Lextreme II]

You can get Stainless from www.speedsource.com
You can get Mild Steel flange from www.boostedsystems.com. However, Joe from boostedsystems is not answering calls or emails for weeks now. Please let me know the price for a set of Mild Steel. In either 3/8" or 1/2".

 

[Philly#1 Lex]

Any word on when we can contact joe? I have been trying to get in contact with him for weeks, no luck. Do you have any other leads on where I can source some for some turbo headers?

 

[elliotaw]

I will email the CAD drawings to my laser cutters tomorrow (monday) and will get him to provide some price quotes in both staino and mild

Elliot

 

[MacroP]

I will also possibly look into getting some copper gaskets for each made at the same time.

Elliot

Has your laser cutter attempted to cut copper before. I ask this because I tried to get head gaskets cut but found out that my friend's lasercutter wouldn't cut copper. Some problem with reflection. Was recommended to use water cutting instead. Haven't done that yet but there was a mob in Perth that would accept Autocad drawings for his machine, hence reducing the cost. Was quoted approx $50 per head gasket to water cut. Copper 1.2mm sheet was around $50 for a 600mm square sheet.

 

[elliotaw]

The company I use have both water and laser machines so I will find out about that, cheers

Elliot

 

[elliotaw]

Got price quotes for header flanges.

Price will be for 2 header flanges, 2 OE cat flanges and 1 emmisions flange.

10mm Mild Steel AU$110 US$84.20
12mm Mild Steel AU$160 US$122.50

10mm Stainless Steel AU$340 US$260.30
12mm Stainless Steel AU$400 US$306.24

1mm copper AU$40 US$30.62

This is pretty much the cheapest I can do, and if I end up making a batch up they will be a lot more on ebay.

Copper can be done in thicker material, but I will have to hunt and chase some down as 1mm is the only size this company stocks.

Stainless steel price is high due to material cost with good surface finish and slow cutting speed.

Obviously these prices are for my own design flanges. I have used 1.5" diameter primaries to match OE exhaust ports. CAT centre hole diameter is 2.5" to match OE cat flange/bore.

I have also not done the header flange to match OE header gaskets as I believe they are not a good design, instead I have designed them as full rounded diamond shape if that makes sense so as to increase pressure against gasket face. I have used a 15mm horizontal gusset between the 4 header ports so each header flange is 1 piece. I can attach a jpg if that helps


Elliot

 

[Zuffen]

Elliot,

I wouldn't bother with the copper flange gaskets and use the stock Toyota gaskets.

They are of excellent quality and can be re-used if you wish.

Copper is not a good material for gaskets as most will know from the problems with coppper head gaskets. Thats why people spray them with aluminium paint in an effort to get them to seal.

I think Lextreme's latest problem with his copper head gaskets is a good example.

 

[elliotaw]

Fair comment. Any idea what new Toyota gaskets cost from the dealership ?

Elliot

 

[Lextreme II]

i can find out, but they are pretty cheap. I would say about $60 a pair.

 

[Zuffen]

I was quoted $93.60 the pair from Castle Hill Toyota in Sydney.

 

[elliotaw]

Might be worth buying a sheet of metal laminate carbon paper gasket material and having some made up if toyota want that much for two gaskets.

Elliot

 

[Lextreme II]

No.... OEM are MLS already. I have seen few after market header gaskets and they are bad. SSAutoc****e has a pair comes with the Tundra headers. OEM is the best. Dont try to reinvent the wheel.

 

[elliotaw]

I will trust your judgement on that one being that you guys have been there and done that. Just like to look at the options, and I might still try to make some anyway simply because it wont cost me anything. Either that or I will clean up the original ones and see how they re-seal.

Elliot

 

[Zuffen]

Elliot,

My standard gaskets have been on and off a few times and they were (I guess) 10 years old when I got them on my motor. They still seal perfectly.

I was advised to re-use mine by a well known Lexus specialist and I'm sure he wouldn't do it if it could go wrong. If they fail to seal he would be out of pocket for redoing the work.

I can't think of a better endorsement.

 

[Peewee]

Are we talking exhaust header gaskets in this last bit?

My extractors don't use gaskets.
I've just got exhaust manifold goo between the flanges and the head.
Exhaust guy did it like this when I had them made, and I redid it after I removed one.
There is no leaking.

The cat flanges are also goo'd.


I haven't tried it with factory manifolds though, but I can't see there being a difference.

 

[Lextreme II]

Here are some pictures of the Lexus-Toyota V8 Header gasket.

 

[elliotaw]

Got my header flange set water jet cut from stainless yesterday.

They've come up really well. I had a few sets made up and will start listing the rest on ebay. Trouble is, after I edited out the background, they dont look like real steel.....hehe

Elliot

 

[SCV8]

Nice parts there.
I was shocked when the Toyota dealer quoted me nearly $50 for an exhaust gasket for my Corolla, found a discount online, was $35 if I remember, but it is re-useable, well made.

 

[Lextreme II]

I need a set of mild steel header flange... Please let me know the price.