Update on my new exhaust pipe tribulations.  

I loosened all the joints and actually removed the 2-1 manifold to make
sure I could get it clean.  Removed large elbow to CAT.  Manhandled the
header pipes until they were as aligned as I could get them. 
Reinstalled 2-1 manifold and gaskets using high temp copper RTV silicone
for good measure.  Reinstalled large elbow with new hardware and
gaskets.  Re-tightened all other connections. Allowed to cure for a
couple of days.  A brief test drive today revealed no leaks, I love that
mellow metallic rasp that a properly muffled engine, especially it seems
a boxer, makes.  Thanks for the encouragement.

A related question; does anyone make a "test pipe" for substitution
where the CAT is and would it help with running and/or power?  My rig is
otherwise stock engine-wise.

Gregory Smith
'88 Vanagon GL

Smith Design Studio
Small Building Company
Olympia, WA
360-239-0429
gregoryfsmith.com

-------- Original Message --------
Subject: Re: '88 Exhaust help
From: Stephen Grisanti <bike2vcu@yahoo.com>
Date: Wed, August 29, 2012 10:23 am
To: vanagon@GERRY.VANAGON.COM, Gregory Smith <gfs@GREGORYFSMITH.COM>

Mine was like this when I replaced it this time last year, the flanges
of the two header crossover pipes met the collector flange at a slight V
angle.  I was able to use some Permatex Copper Spray Gasket (recommended
by one of the Advance Auto guys) and load up the mating surfaces
adequately for a good seal.  Still holding.  

After I was done, someone wisely suggested that I should have
belt-sanded the uneven mating surfaces to try leveling them and had I
thought of this before testing successfully I'd have done so.  Try
belt-sanding first and use the copper stuff as insurance.

Also, the other reply about loosening everything up and tightening it
all incrementally is a good idea in any case.  That way, you do not
preload any single piece in the wrong position. 

Stephen

--- On Wed, 8/29/12, Gregory Smith <gfs@GREGORYFSMITH.COM> wrote:

From: Gregory Smith <gfs@GREGORYFSMITH.COM>
Subject: '88 Exhaust help
To: vanagon@GERRY.VANAGON.COM
Date: Wednesday, August 29, 2012, 11:52 AM

Hi gang,

I recently had to replace my header pipes and 2-1 manifold.  I'll spare
the horror stories of getting the old rusty parts off.  Except to
mention the one broken stud that took more than 4 hours to coax out
using heat, PB Blaster, vice grips and patience.  And a sawzall is sure
handy.

Anyway, the new pipes and gaskets are great, but I can't seem to get the
dual-pipes-to-manifold joint to seal, where I have a noticeable leak.  

I think I need to loosen everything and start tightening at this
particular joint, but any suggestions are appreciated.

Gregory Smith
'88 Vanagon GL

Smith Design Studio
Small Building Company
Olympia, WA
360-239-0429
gregoryfsmith.com