Header flange is warped, best way to mate to the head??

[Wheel House Motorsports]

Just fyi, its a 1 ton motor, so its a pretty long flange. When I built my new header this summer, the flange on the motor side had a TINY big of warpage to it.. even with a good straight edge, over the whole length the thing the out of straightness is `1mm at most. When I I installed it I copper gasket sprayed the chit out of both sides of the gasket, and it seemed to seat well and not leak. now after riding it a few hundred miles im noticing that there is black all around the edges of the exh ports at the header gasket. it also obviously blows steam out when its starting in the cold. I pulled it off and was curious what the best way to remedy this is??

Could I double up 2 gasket without risk of blowing them out?? Right now until i either descide on another gasket, im just gonna load the copper spray on nice and heavy on the gasket and mating surfaces and reinstall, but I was curious of a more permanent solution, if this one isnt. A new header would be nice, but at around $250 in just materials to build one, no thanks.

And while your reading, would a leaky header lead to a lazy out of the hole and boost fading under load?? seems like what I read, but just curious.

thanks guys

 

[blackhillsnytro]

since all of the welding is done, take it down to a machine shop and have them shave it down a bit. I have done the same thing in the past, was a cheap fix and the problem was solved.

 

[Mountaintech]

since all of the welding is done, take it down to a machine shop and have them shave it down a bit. I have done the same thing in the past, was a cheap fix and the problem was solved.

X2. Take it to your local machine shop and have it milled flat.

 

[Wheel House Motorsports]

thanks, i totally forgot about stuff like that. dropped it by the local engine builder.. gonna throw it on the machine and smooth it down.

between the flange not seating right and the few tiny cracks/holes in the pipes, its gonna really be a wild sled again!

 

[Polarisrocks]

Hey I had a boondockers warped header and I descided to have a few gaskets made since i was the 1st one they ever heard of... LMAO
Remember the more you take off that flange the more chance for warpage... hope they are careful..

So i had a local company make me a Rem flex apex gasket. They are designed to seal warped headers. they have a 50% squish rate and a 3000F burn rate. I have sold over 22 of them and only have 2 left. I also have the gaskets that mate the header to the turbo. If you are interested shoot me a pm..
http://catalog.remflex.com/ here is link that showes who made them, 100% satisfaction guarantee.
Thanks Jim

 

[t_thall]

I just used an autobody "straightboard" with 80 grit, worked good

 

[Wheel House Motorsports]

it was kinda bad.

they had to tke .050" off the motor side and .015 off the turbo flange..

took it out this afternoon, my boost controller actually works, so it definately helped a lot. and the thing runs a LOT cleaner up top.;

 

[Mountaintech]

How thick are your flanges?