http://Instagr.am/p/UeawTQPKoL/

That's a link to my instagram of my warped header. I searched the forum,not many results in the same spot as mine.
So Here's the thing, I don't know someone who Can fix it, plus I don't really want to buy a new set I just got these in the fall. My car's been sitting since November. So I don't know how long it's been like that.
It blew my mr Percy header gasket in minutes.

So this being the best Internet website to go to, anyone know any tips or tricks to seal it without major modifications or hurting my pocket?

 

resurface the flange.

 

Weld in a wedge to fill the gap.

 

Clamp it to a flat,strong surface and carefuly heat it and work the flange flat.

 

cut the flanbge between the outer primaries and the center pair.

 

Take it to a machine shop and have them slap it on the big belt sander till shes all flat.
Also, use felpro 1404 or 1405 header gaskets and 1" long bolts with a lil anti seize on the threads.

 

ive heard this before.

 

that seems like a good idea until you try to bolt it up to the engine and you find that one or both of the outer tubes has bent up/down/forward/backwards from where it's supposed to be and you can't get the bolts to start.. been there, done that, cross threaded the bolt into the head- but never got the t shirt..

is the header hitting the frame anywhere? are the bolts to long, and not actually clamping down tight?
try taking the gasket out and bolting it up tight and see what happens- if you can get it tight that way, then it will clamp down tight with a gasket in there.

 

No the header isn't hitting the frame. Everything is tight, the homemade y pipe that was made for me is horrible. But it was temporary. My mechanic says it looks like it pulled the header away from the engine block, and that a new y pipe should fix that. I'm getting one Friday or Saturday.

 

I've done this before- it's the way to go! you probably didn't warp it....it was probably not right to begin with, but who would actually put it on a straight edge before you install it the first time? I do! too many of these new exhaust parts are NOT flat. i hate having to do things twice! bring it to a shop and get it belt sanded once. you will probably never need to get it done again.

 

3rd vote for belt sander.
My buddy has an 84 Z28 he was always having problems with his header gaskets blowing out. He took to our local machine shop, they said they see this all the time. Trued them up on the belt sander and its been fine for 2 years. They recommended the dead soft aluminum or copper gaskets.

 

Just a note you probably didnt blow out the percy gasket. Its aluminum so its a bit hard to actually blow it like a paper gasket. You def have a leak there but once you fix the warp i bet you can slap it back together with the same gasket and be golden.

 

Didn't know this was possible.

 

Do you have the percys with the smooth sides towards the headers? Swap them around

 

It looks warped pretty far. Hopefully there is enough material to sand flat. Else may need to bolt to head and cut flange to move it flat, then reweld together, then resurface at machine shop

 

The inner bolt on the short side of the radius looks like it's cross threaded also.

 

The exhaust shop thinks it to warped to resurface. Uh oh

 

Actually I don't think it's pushed down far enough to even cover the hole

 

tell em to lean on it more while sanding- it'll go flat!

 

In that case i would find an old head, carefully bolt it on and cut flange. Use heat and bolt pressure to bring it straight and reweld flange together. Then resurface.

Or buy a new header flange and cut the tubes off and reweld a new flange on