Thanks Scott,

Yes I like the idea of dbling up the gasket. Obviously I did not get a
good seal there on the cast iron joint. And it's kinda hard to see for
sure if you are getting a good mate with the surfaces, so in some ways
making the adjustment now, eg with the engine in the car, where i can
fire it up and confirm no leak has it's advantages. The leak appears to
be the joint where the forward header connects too.

-john

On 4/23/2011 8:06 PM, Scott Daniel - Turbovans wrote:
> hi,
> no sealant on the exhaust gaskets.
> ( they don't need it, and oxygen sensors can get ruined by some type
> of sealants )
>
> sometimes, on that cast iron junction piece, it's normal to need
> double gaskets on one of the pipes ..like usually they 'forward
> cylinders' pipe .
> I've seen that a number of times.
> so see if that might make a better meeting of the pipes there with
> that cast iron piece.
>
> nut type doesn't matter too much.
> non-copper ones tend to rust in place after a long time. Copper is a
> better material to use there for sure.
>
> it's normal always to retighten all exhust fasterners after a few
> warm-up-cool-down cycles.
> Just don't break off any studs that screw into the heads or anything ..
> but for the nuts and bolts ....tighten them very firmly by hand.
>
> always use copper anti-seize compound ( or aluminum, but copper is
> better ) on the theads of all fasteners on the exhasut system.
>
> I suspect your aftermarket pipes might not fit that well.
> there is some tendency to 'normalize' after numberous heat
> cycles...then thighten nuts and bolts more.
>
> see if two gaskets on the forward pipe isn't something that would
> help,. at that cast iron piece.
>
> laying on your back under the ( van elevated some ) is a comfortable
> way to work on them.  Creeper helps of course .  I sure like that
> better than van on a lift where  you are working with your hands over
> your head looking up . On a creeper ...things are right in front of
> you , nice n' comfortable.
> Or lay on a large piece of cardboard perhaps.
>
> scott
> www.turbovans.com
>
>
> ----- Original Message ----- From: "John Goubeaux" <john@UCSB.EDU>
> To: <vanagon@GERRY.VANAGON.COM>
> Sent: Saturday, April 23, 2011 7:18 PM
> Subject: Pesky Vanagon exhaust system.....
>
>
>> Any exhaust system experts have any advice to offer?  I just installed a
>> new 2.1 engine in a 90 and ( with engine out) bolted on new exhaust
>> header pipes and the heavy elbow flange that joins them together on the
>> LH back corner. It was a bit of a bear to get em all to mate up
>> properly, but with a lot of loosening and tightening and coaxing I
>> thought I got em all snug ( poor fitting aftermarket parts I'm
>> thinking). Well after start up it looks like I have an exhaust leak at
>> one of the connections to the large elbow flange.  Damm - I'm thinking
>> these were hard enough to mate with engine out, now I have to do it on
>> my back  and looking up !
>>
>> So are there any tricks here ? Use a gasket sealer along with the
>> regular flange gasket? Are regular nuts better than copper as it might
>> be easier to tighten them down more ? I used copper thinking they were
>> superior. Maybe I just need to use a bigger ratchet and tighten the crap
>> out of the bolts, at the risk of breaking a bolt though. Maybe it's not
>> uncommon to have to loosen/re-tighten them after a few heat/cool
>> cycles ?
>>
>> Any sympathy and or suggestions appreciated.   -john
>