I had a similar problem on my '84. First, I took a big bastard file and
tried to file the flanges flat, but they still didn't line up parallel to
their mates.  So, I used a two gasket sandwich with hi temp silicone and
that worked very well.  The extra thickness compressed and filled the wedge
shaped gap between the mating flanges.

A proper, but more expensive solution would indeed be to cut off the
flanges, file or grind flat, bolt them up, and weld the pipe back on.

Stuart

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of
Michael Diehr
Sent: Sunday, July 13, 2008 9:02 AM
To: vanagon@GERRY.VANAGON.COM
Subject: Stubborn Exhaust leak

85 vanagon with exhaust leak at the junction between the two header
pipes and the collector pipe (part #G on this picture:
http://www.bus-boys.com/vanwasser83-91.html
  )    I removed the parts, sanded off the remains of the gaskets,
installed new gaskets, bolted it back together and... it leaks just as
bad as before.   Took it apart again --   The collector pipe (G) seems
ok, but the ends of the header pipes are pretty rusted, and I can see
how it may be difficult for the gasket to seal.   Tried some high-
temperature metal gunk to fill in the gaps, then reassembled but
didn't really seem to help :(.  FYI, I put the metal side of the
gasket towards the collector as that seemed the most logical and
seemed to match the prior parts, though Bentley was not clear on that
topic.

I'm tempted to take it to my local mechanic, hat in hand, and say
"make it work!" but I haven't entirely lost faith yet.   Is the
solution new header pipes?  A MIG welder? :)