I've finally got my car running smooth again after the top end rebuild...although, the rusted studs on the exhaust manifold on the driver side are keeping me from bolting them up all the way and there is a small gap...when I rev the engine everything sounds fine, it's smooth, it sounds like it should. But when I let off the gas it pops, crackles, and flames come shooting out of the opening between the manofold and the y-pipe...I've even seen them go all the way up to the hood...here's a video of it...seems like a simple problem that I'm just not catching...what do you guys think?

http://www.youtube.com/watch?v=RVC2kbyvSU4

 

What's to "think"?

I don't even have to look at the video to have a suggestion. I "think" you should just fix the leaks, same as you should fix any other leaks. Replace the studs if necessary.

 

...

 

I figured it was as simple as that...but I jacked the y-pipe up tight against the manifold...no leaking...and it still cracked and popped just like before.

 

It may have looked like it was sealed, but there are gaskets there for a reason. Short of those ball & socket style sockets (which we don't have), you need a gasket.

 

The flames are from the hot exhaust coming in contact with oxygen in the outside air. Once there's a gasket in there and its tight you shouldn't have a problem.

 

I've got gaskets on at the cylinder heads. The flames are coming from where the manifold hooks to the y-pipe. There isn't a gasket there that I've ever been aware of...I'll rig it all up somehow. just need it to last long enough till I can pick up headers and y-pipe from buffaloman. Maybe I'll bust out the mig welder tomarrow.

 

Yeah, those manifolds may have that ball flange where you don't need a gasket. I dunno

 

Mine had Donuts for gaskets at the bottom of the manifolds.

 

I do have the ball and socket, I'll see if I can pick up somekindagasket for it.

 

Some of these cars had ball and socket with a donut. How much gap do you have there? Kinda hard to tell from the video.

 

the gap is about half an inch. but when I put the jack under it and pushed it up the gap was gone altogether. it appeared sealed to me.

EDIT: I check with autozoen and they do have a donut gasket for the ball and socket connector. but I know mine didn't come from the factory with one...