Hey guys I was wondering if anyone else has had their fd seem like it has a non stop exhaust leak? My gasket between the turbo and manifold was split so I did replace it to a duel layer but the leak is still present. A friend of mine, who I is a real good mechanic, said that to tighten the bolts down some more but if that doesnt work that its possible the manifold could be warped. He said that he did check the gaskets. So im wondering has anyone had this happen? My manifod is from full race.

 

have you taken the manifold off and put it on a flat surface to see if it is "true"?
You may need to get it milled,so it mates better.(my guess anyways).

 

Most likely the manifold has warped flanges.
My 2004 single turbo kit has that problem on both ends of the exhaust manifold.
It was not machined after the welding which caused warpage.

 

Sounds like an easy fix if it's a warped flange. Machine shop should be able to mill it flat for fairly cheap. Surprised it came like that from a company as reputable as them..

 

It can happen with any company, to be honest I've had a few go out. I've had a few full race manifolds have it as well on honda applications and a few other well known companies as well. It is more of a possibility when companies use stainless flanges as well.

~S~

 

Never had any issues with full race on my s2000. Good customer service too. I guess it can happen though as you said. I just figured they'd check and mill after welding.

 

Yep happens, K20 manifold, subaru manifold, if they take care of it that's what matters.

~S~

 

So if it doesn't go away after fighting the turbo to manifold some more you guys suggest yes that it's warped? But a local machine shop should be able to take care of that?

 

Either a machine shop or someone who's good with a 6" belt sander. Machine shop is best though since a belt sander can make things worse if you're not familiar with what you're doing.

~S~

 

Right. Well hopefully if just needs to be tightened down the manifold is still pretty damn new.

 

Most places will use a belt sander, you might also want to check the turbo itself.

I recently bought some weird liquid gasket stuff from the company DEI. The gasket from engine to manifold was leaking on our e46 time attack car after our first test day with new turbo setup. We got the manifold resanded and used the dei liquid gasket maker stuff and we have no leaks now. It's not an endurance race, but we get the exhaust super duper hot!

Most places won't mill it unless you can grab the piece properly. Most of the time you will see even quality companies with their products belt sanded

 

That stuff can be bought mostly anywhere?

 

Is it the high temp silicone coating spray?

 

It's called spa gasket eliminator. You mix it with a little bit of water, weird stuff

 

And it's from dei?

 

Yeah, do a quick search and it will pop up. Make sure you check your flanges for straightness though. We used the original gasket and added this stuff AFTER we got the flanges sanded

 

DEI 090400 DEI SPA Gasket Eliminator and Flange Sealant - Free Shipping on All Orders @ JEGS

 

Cool man appreciated

 

We face all our manifolds after welding. It is very easy for the flanges to become slightly distorted from the welding heat. I also prefer steel flanges because they are more resistant to warping.

 

This company DOC race makes a 3/4" thick flange now! fd only though. I believe they use schedule 40 tubing, maybe thicker, heavy, but heavy duty. Just thought I would add that

 

Is possible that my new duel layer gasket would blow after a couple of starts?