Pacesetter Shorty Header Install, can't stop leak at flange
 

So I finally ordered the Pacesetter shorty headers from Summit Racing that they brand as their own. I stripped the paint off and repainted using VHT Header Paint as well as wrapped the set and Sprayed wrap using DEI's kit. I used locking header set from Stage 8. I used manifold gaskets from Felpro not the cheap-o set that came with the Pacesetters.

Anyway I did everything right and I still can't get it perfect. I cannot get the Driver side exhaust flange to stop leaking. I did manage to get the Passenger side to seal properly. The new headers port or flange diameter is definitely bigger than stock, but as i said the passenger side seals so I don't understand why the Driver Side wont. There were no Doughnut Seals on stock, and the new headers didn't come with any so I imagine they aren't needed.

Muffler shop is closed today and i was supposed to go wheeling this afternoon. Any words of wisdom?

Get the dead-soft-aluminum gaskets. Put 'em on, torque 'em down, end of leaks.

Just to be sure we are talking about the same thing, it is leaking where the header meets the y-pipe. So you are saying get a dead-soft-aluminum doughnut style gasket? Can i get one from autozone?

Ah, I thought the leak was between the header, and the head..... Did your headers just have to rounded end, the pipe is supposed to bolt up to?

I've had Pacesetter headers installed on my truck and they are not the most exacting fit headers made. I had issues getting those headers to align properly with the stock exhaust Y-pipe. I ended up using a port-a-power with a Y-type expansion end to align the flange on one side to properly align so I could stop that pesky header leak. Check the alignment at the flange and make sure the header flange and exhaust pipe align properly, then tighten the bolts enough to stop the leak.

I believe the dead cooper gasket that HeyYou is referring to is the gasket that goes between the header flange and the cylinder head. Those tend to be special order from SCE, which can also be found at Jeg's, Summit Racing and other well-stocked speed shops.

Use a Remflex gasket

My truck had edelbrock shortys on it when i bought it and they leaked so bad at the head it was crazy ! Then when the trans went out 6 months later i put stock manifolds on it and no more leaks !

All set, just took it up the road to a muffler shop, they cut the y pipe ends, bolted them to the header collectors and welded a new sleeve to re-attach the y-pipe ends to the rest of the exhaust. The new headers were at different angles pulling the y-pipe in awkward angles and causing a leak.

For future folks, the felpro gaskets paired with the stage 8 locking header bolt kit is the way to go. No leaks bolted up easily.

What did you use to strip the header paint?

REMFLEX gaskets are the way to go... torque and forget, no leaks.