Blowing Exhaust?

[MiniMan64]

In the next few weekends I'm planning on stripping out my exhaust system for a bit of a clean up and to properly seal up a few blowy joints.

Unfortunately I know it's also blowing from where the manifold goes onto the head (the inlet is bright orange and there's a lovely black stain there) and I had a quick look today. Bit odd though because it looks like the inlet manifold is 'thinner' than the exhaust manifold so where the thick washers and bolts are meant to be holding both in place, they are only holding the inlet down tight and there's a slight blow from the exhaust.

Looking at today I can't see a reason for it other than the differing thickness. At the moment I'm hoping once it's out they'll be some bit of crap there or something stopping it sealing properly and with a new gasket it'll be a nice tight fit.

Any other suggestions?

[Minivanman]

I cut a few washers in half and used them to make up the difference in thickness between the two. The thick washers can pull them both down properly then.

[nightrain]

As above and it's a good idea to weld 'em to the thick washers, won't get lost. You can file/grind one half of the thick washer down creating a step. You can add a blob of weld to the exhaust flanges and grind back as required.

The one thing you DONT want to be doing is filing the alloy inlet manifold flanges down. This will make them to weak and they'll snap off.

[Minivanman]

I'm gonna weld mine together next time its off, its a right fiddle to hold the half washer in place and tighten the nut up as well.

[nightrain]

Actually it's a lot easier to weld the half washers to the exhaust manifold flange thinking about it.

[MiniMan64]

Cheers lads, I'll give that a crack. Funnyily enough some of the washers are already shaved off to a flat edge so they'll fit againt the manifold.

Now I've just got to get the damm thing off, I've a funny feeling that the link pipe between LCB and the back box is a scabby piece of scaffold pipe that's seen better days!