Need to make exhaust manifold gasket, extremely high heat

Like the title says, i need to make an exhaust manifold gasket. Remflex is out, it's too thick for this application.

I think i need something like what's labeled "Berk" in here. (Also: HAHA!! BERK!)

Pretty much every "DIY" kit i see is paper crap, and i somewhat doubt that's going to hold up in this scenario. OEM gasket seems to have a fire ring. How important is this?

Get some rotary stuff, you know that will hold up to the heat. I have had the same gaskets on my Racing Beat street-port exhaust for over 10 years now, and they hold up great.

What is rotary stuff, though?

Racing Beat,Mazdatrix,etc... I imagine there must be something that is close to or exactly the size you need from Racing Beat. My exhaust is from them, and the rotary gets really hot especially the turbo stuff, and I have not heard of major gasket issues with their stuff. Like I said my RB exhaust is over 10 years old ,and on its second vehicle with no gasket issues.

I think i worded this wrong. I need to make the gasket that goes between the head and the manifold. There won't be anything pre-made available.

Any idea what sort of material your stuff is made from?

Copper sheeting works very well.

http://www.mcmaster.com/#standard-gaskets/=qs36ol

Bobzilla linked me this stuff: http://www.summitracing.com/parts/php-68070/overview/

What do we think?

Or you could just do what some Chryslers did - make sure they surfaces are flat and use no gasket. Doesn't work with headers - the flanges usually warp.

wspohn wrote: Or you could just do what some Chryslers did - make sure they surfaces are flat and use no gasket. Doesn't work with headers - the flanges usually warp.

No gasket between head and manifold?

foxtrapper wrote: Copper sheeting works very well.

Dito on copper. It's melting point is north of 1800 degs.

Swank Force One wrote:

wspohn wrote: Or you could just do what some Chryslers did - make sure they surfaces are flat and use no gasket. Doesn't work with headers - the flanges usually warp.

No gasket between head and manifold?

Most American V8's with cast iron heads didn't use gaskets, and if you put them in, they would blow out right away.

I'll vote for copper as well. If you have a standard type gasket as a pattern, there is likely a waterjet guy around that can cut it for you. You could do it yourself too, but I find that fiddly stuff boring.

Streetwiseguy wrote:

Swank Force One wrote:

wspohn wrote: Or you could just do what some Chryslers did - make sure they surfaces are flat and use no gasket. Doesn't work with headers - the flanges usually warp.

No gasket between head and manifold?

Most American V8's with cast iron heads didn't use gaskets, and if you put them in, they would blow out right away. I'll vote for copper as well. If you have a standard type gasket as a pattern, there is likely a waterjet guy around that can cut it for you. You could do it yourself too, but I find that fiddly stuff boring.

I know this is a little dumb to ask on the internet instead of a local place, but any idea how much that sort of thing would cost?

I'll be able to provide them with a pattern of some sort.

Spoolpigeon wrote:

Bobzilla tells me that's only rated to 800F.

That's not gonna cut it.

My local waterjet guy could do it for $20 or less if you supplied materials and a DXF file of the flange.

I have had them made from thin 0.060"-0.080" 304 stainless steel for between the manifold and turbo before and they always worked great.

Swank Force One wrote:

Spoolpigeon wrote:

Bobzilla tells me that's only rated to 800F. That's not gonna cut it.

Really? Damn. All those warped headers and such that I've successfully sealed with it over the years. Guess I'll have to tell them they aren't working.

Seriously, the stuff works quite well, though it won't hold up a gap where the exhaust gasses are directly burning it.

We use this stuff at work: http://catalog.remflex.com/

You can buy the gasket material in bulk and it's good up to 3000 degrees.

It's easy to work with, I've made a few manifold gaskets with it now.

Looking at the "new berk" in the pic at the top, I think it's the same material.

Shawn

In reply to foxtrapper:

I was giving Swank E36 M3 because we used a ton of it on a challenge car we were working on

In reply to Trans_Maro:

The "new berk" looks more like my oem head gasket material.

Remflex is just too thick for this. I have it between my turbo and manifold though.

In reply to Spoolpigeon:

I already ordered new gaskets for that E36 M3.

FWIW, on the turbo motorcycle project in my garage, all I did was machine my exhaust flange true, add a layer of the copper goo and tighten the bolts.

This is where my exhaust header meets the turbine inlet.

I haven't started it yet but I should have it running next month.

Shawn

Trans_Maro wrote: I haven't started it yet but I should have it running next month.

Famous last words.

I know, I said that a couple months ago.

I forgot to add "And this time I mean it".

I've only had the engine apart three times now....

foxtrapper wrote:

Swank Force One wrote:

Spoolpigeon wrote:

Bobzilla tells me that's only rated to 800F. That's not gonna cut it.

Really? Damn. All those warped headers and such that I've successfully sealed with it over the years. Guess I'll have to tell them they aren't working. Seriously, the stuff works quite well, though it won't hold up a gap where the exhaust gasses are directly burning it.

Agreed. Have used Ultra Copper successfully on a bunch of header to head surfaces as well as header to sidepipe flanges on the Cobras. Let it begin to skin over a little before assembling.

Jeff