Need a pep talk/help: can't eliminate exhaust leak after 5 attempts Options

[DC_neun_vierzehn]

Looking for some advice and encouragement because I'm ready to say "uncle."

I have a '73 2.0 w/ a fresh 2056 rebuild. Exhaust studs are new. I have new exhaust stud nuts from @rhodyguy . I have new Victor Reinz copper washers and exhaust gaskets. My heat exchangers (HEs) are stock (not stainless).

By using the shop vac blow up the tailpipe method, I have detected exhaust leaks on the passenger side (PS) at both exhaust ports as well as at the muffler gasket.

Here's the method I used on the driver's side (DS) and it worked perfectly: a dab of Elmer's glue on the copper washers to get them to sit in the heads and used the X pattern to tighten the nuts moving to the next nut after 3 rotations. Worked perfectly, no air leaks.

I tried the same method on the PS HE, but it failed to eliminate the air leaks at the head after 5 straight attempts of removing and reinstalling. SO FRUSTRATING.

Based off of past threads I found via the search, the only things left to try:

1. Gently file the HE pipes to square them off (use a Sharpie to mark the tops and only file until ink is gone using a large bastard file that will do both pipes simultaneously). I did not do this yet because the pipe ends look flat and clean. When I set one of the copper washers on the top of the pipes they sit flat and even - when I shine a flashlight behind that I don't see any light coming through.

2. Anneal the copper gaskets using a blowtorch - I have no idea how I would get the copper gaskets to sit in the heads after annealing them and then lay on my back underneath them while trying to install the HE sounds a burn victim waiting to happen. How does one do this safely?

I'll take any suggestions or encouragement because after spending 4-5 hours on this today, I'm feeling a bit hopeless.

[914_teener]

I went through this same issue but with the SSHE's.


made sure everything is in the same plane using the same methods.

Slits gave me this advice:

Took High temp gasket sealer at your FLAPS copper based .. then inserting the copper gaskets and placed them in the ports..made sure there was no excess into the ports by taking your finger and wiping them clean. Then another seal of the high temp gasket sealer...then wiped with your digital meter...finger...then carefully torque the nuts in sequence. I used a floor jack to aligh and hold everything up. Alot easier to do also with a lift...almost a must.

Never leaked after this.