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Old 05-18-2003, 02:44 PM   #8
84LX89GT
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Join Date: Jul 2000
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Part of the reason header gaskets blow out is because they are thin paper and even a small amount of clearance will blow through the side of them....what causes this is that headers warp up over time. The ones on my car have warped and luckily haven't leaked yet. All headers warp, some just warp less than others. When you take the header off, take a straight edge and take a look across the ports of the header, sometimes using a feeler gauge will help find trouble spots. Also, using a copper header gasket helps alot because it is thick and tolerates more variance in the surface if you decide you don't want to mill the headers down flat again.
One of the reason headers warp is that they heat up really fast and cool down really fast, this tends to warp metal. Also, if you don't torque down the header bolts evenly this will aid in warping the flange.
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2005 Suzuki Hayabusa GSX1300-R

1980 Ford Thunderbird - 255 V8
ported heads, 5.0L ported stock headers, O.R. H-pipe and Flowmaster 2-chambers, dual roller timing chain
hi-po Mack Truck hood emblem

1985 Mustang GT 5.0L T5, F-303, GT40p, headers, off-road h, flowmasters, MSD stuff, etc.

Sold 02/06/04
1989 Mustang GT ET: 13.304@102.29 mph (5-24-03)

Sold - 1998 Mustang Cobra coupe, 1/4 mile - street tires: 13.843@103.41 (bone stock)
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