Dansk exhausts have always been like this, it's a design feature they built
into their jigs.  The set I put on my 2.1 12 years ago was a 1.9 exhaust had
that flange problem too.  I ground off some of one side and used two gaskets
and exhaust sealant which seemed to work well.

Stuart

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of
Alistair Bell
Sent: Wednesday, July 24, 2013 8:57 AM
To: vanagon@GERRY.VANAGON.COM
Subject: Re: exhaust leak, header tubes to collector on 2.1 engine

I was stupid not to.

Engine was out of van when I installed them (all except the collector). I
*thought* the mis-alingment was not that bad. With engine in, and needing
the van as a daily driver, I was reluctant to pull them off. So truthfully I
am annoyed by my own actions and by Dansk equally :)

cheers

alistair

On 2013-07-24, at 8:26 AM, OlRivrRat wrote:
                Alistar

        Why didn't you return them?

                        ORR ~ DeanB

On 23 Jul , 2013, at 10:50 PM, Alistair Bell wrote:

> I recently installed Dansk front and rear, plus collector, pipe on my
syncro. Terrible fit where the flanges meet at the collector. The pipe
flanges are not on the same plane, rather they are angled back, like a
dihedral. I tried stacking gaskets but no luck, still leaked. I would have
to grind off a fair bit of the pipe flanges to make them coplanar. I'm
toying with the idea of oxy-acetylene persuasion but probably will try
machining an angled "gasket" from mild steel. Meanwhile I used the tube of
goop David mentioned (Kleen-flo brand) and a little bit of rolled up ss mesh
to fill the gap. Then a bent strip of ss plate to hole the mesh in place and
the strip held in place by 2 right angled brackets attached to the flange
bolts.
>
> A real kludge if there ever was one. I'm really annoyed by the bad fit of
the pipes.
>
> alistair