i doubt its the gasket the oem gasket is a multi layer gasket that crushes down when you tighten it. i have re used OEM exhaust manifold gaskets on all my turbo honda cars, and i've had about 5 or 6, each with more than one setup. the flange is probably warped from when it was welded and wasnt surfaced properly. when i built my manifold for the s2000 the flange warped like crazy even thou i welded it when it was bolted to a heat sink. you need to blue up the manifold mating surface, then run it alone a big belt sander for a few mins. after that if you still see blue in some areas then that is where it is warped. keep sanding until the surface is flat.

look how warped mine was after i welded it...

 

Just get it machined true.

Nothing like starting with flat surfaces.

 

Mase has to machine all the flanges true after welding. Pang forgot yours

 

dont bother with that type of gasket, you will see how cheaply made it is when you hold it. Pretty much cardboard w/ some foil on either side

 

So you're saying he does this on all of them?

I don't want to send it back. It was almost falling out of the box when I got it... no telling what will happen if I send it back and wait for it to return.

I wish I knew somewhere here that could do it.

 

Post up on a local car forum asking for good machine shops.

Around here, some Napas and Carquests have machine shops in the back. Call a few in your area and see if they have a machine shop.

 

Well, I found one and the guy said it'll $80 maybe more because he'll have to use a belt grinder (or something) and he'll need a new belt after.

He took a straight edge to it and he laughed. Guess my manifold got forgotten about when it came to making sure it was straight.

I wonder if Pang/PFAB would be willing to pay for this... It's not fair that I had to take my car back apart for something that should have been done.

 

[QUOTE=AFs2k,Nov 30 2010, 05:23 PM] Well, I found one and the guy said it'll $80 maybe more because he'll have to use a belt grinder (or something) and he'll need a new belt after.

He took a straight edge to it and he laughed.

 

send it back and just put in a bad ass thick cardboard box and wrap it well. i am sure it will survive the trip and cost you way less.

 

I already left it there at the shop. I need to get my car done. I leave in less than a month.

There is no way he can't stand by the warrenty. It's not my fault it wasn't done... Why should I have to wait for weeks for something I can take care of here. I'm sure he'll agree. If not... well, then I will send it back on fire. (or something.)

I sent an email and haven't gotten a response yet.