So I finally got my TTI longtube header kit installed, turned out the engine had to be lifted a smidge to get the passenger side to slide in. Got everything on well and good and was pretty excited. Brought up the RPMs to check for leaks, heard nothing. Start driving it down the road - TAP TAP TAP TAP TAP TAP.

Retightened all the bolts. Shortly after driving again, TAP TAP TAP TAP TAP. I've made sure the bolts were on good and tight about 4-5 times now over a course of 150mi. Passenger side taps and it's driving me freaking nuts. I even snugged down all the collector flanges twice and it's still doing it. The TTI gaskets look good and the header flanges were flat.. what gives!!! driving me insane I can't even be happy about the giant wad of cash I dropped on my new headers!

 

I ordered a set of remflex gaskets...maybe they'll help. Not sure what else to do. I don't see any carbon from a leak

 

Well, it sure sounds like an exhaust leak, but if the flanges were good and you've got the bolts tight, dunno.

Surprised you had to touch the engine mounts, never did with the Pacesetters...

 

yeah supposively the remflex gaskets have some good flex to em, hoping they make the difference. Though the TTI gaskets seemed pretty high quality..

 

OEM mopar gaskets are the only ones worth it.

 

x2 on OEM gaskets.

 

Yeah, I used the cheap paper ones that came with the Pacesetters, I probably should have gotten the OEM ones, but I set out to do the install on a sunday and was impatient. I just figured when they tore up, I'd get the Mopar ones and re-do it. Amazingly, every time I've checked the bolts they've still been perfect, probably cause I don't go very long so the bolts never have a chance to loosen and tear the cheap gasket. Going on five years now.
Must have been the real good installer I went with (LMAO)!!!

 

Sounds like my Mustang. I put a set of MAC shorties on it in 1990 with the supplied paper gaskets. The bolts have worked loose several times, yet they have never leaked. I only had to change gaskets last fall because I pulled the motor to install another. Heck, if they wouldn't have torn when I removed the headers I may have reused them
So I'm thinking that 20 years and 130K miles is a pretty good lifespan for a set of header gaskets.
I had to use a set of copper gaskets on a friends 68 427 Camaro to get the 2" tubed Hookers to seal.

 

How hard is it do install headers on our trucks? Do they bolt right up the the stock exhaust system or do you have to do a fully custom exhaust system?

 

Are you sure it's actually a leak??
I installed shorty headers on my truck and the first thing I noticed was the tapping sound. This is common as the primary tubes are larger than OEM plus they are a thiner metal vs the cast. The sound actually echos inside the tubes making the tapping sound much more prominent. I first thought I had a slight leak, but there is no leak. I re-used the OEM gaskets and have had them on for 6kmi and there is zero signs of leakeage anywhere around the perimeter of the gasket. I can hear my valves as well as the notorious Hemi Tick through the thin header metal.