Alright guys, I need some help here.

The header is sealed and working fine with no leaks but I'm getting a little irritated at the header to downpipe gasket that keeps blowing out.

I started out with the 3", 2 bolt gasket that came with the kit. Ended up blowing it out within just a few days. Replaced it with another exact replacement. Again blew it out in about 3 days. Replaced it again with another exact piece, but this time with Permatex Ultra Copper sealant. Held up for about 2 weeks then blew out. Now I'm sitting here with yet another new gasket, some leftover copper sealant, and a headache. If this one blows out, I'm going to say **** it and take it to a local performance shop to cut off the (why the hell did they ever use) 2 bolt flange and weld in a 3 bolt flange.

Any one with any suggestions before I go for the final 2 bolt gasket install with a shitload of copper sealant? Every time it blew, it blew right out of the side where there is less hold from the bolts.

And before anyone asks, yes I tightened the **** out of the bolts during install.

 

just go with the header downpipe combo, it's about the same price and installs pretty easy, (45minutes-1hr) at your local shop. plus...less gaskets

 

?? no no i already have the zzp midength header dp combo. im only talking about the gasket blowing

 

oh okay, i thought you meant where the header meets the dp, my mistake

 

thats wat he is talking about

 

could be that you exahust is hanging akwardly and causing you header to bend downward creating a slight leeak that build up under pressure.

 

any sounds clips?

 

i dont think its hanging in an awkward position. header is flush mounted and im using the stock cat back on the stock hangers. and its all nice and centered along the tunnel

sorry no sound clips. just sounds like an exhaust leaking from the blown downpipe gasket

 

mine installed fine at local mechanics shop...no issues for like 3 months...

 

i had the same problem, i called them.. they have recently changed the bolt sizes on the header to d/p to fix that problem. call them and they will send you the new 3/4'' bolts. the thing that sucks is the bolts will go through the header ok, but they wont go through the dp holes. so i had to take off the dp, and drill out the holes some in order for it to work. that fixed the problem for me

 

3/4" bolts? After snapping the "upgraded" bolts from ZZP within a couple hours, I went to Grade 8 bolts that are 7/16" X 2.5" along with some 7/16 SAE Thru hard washers and nylock nuts. The combo fits perfect, no drilling of the downpipe, and it holds up. The original "upgraded" bolts wernt even close to being the right size, there was so much play I believe thats why the bolts are breaking.
Im assuming the play with the bolts in the holes are allowing ur dp/ header to move just enough where its causing the gasket to blow out. Kinda wierd though. Too bad u didnt have pix.

later

 

I actually did the same thing with the bolts.

The "upgraded" bolts that came in the kit snapped the second day I had them on. Ran an open header for an hour drive from Dayton back to Columbus... got a headache. Went to Pep Boys and got the exact same grade 8 bolts you did and haven't had the issue again since. The bolts are more than strong enough for the hold but the problem, I think, is the fact that they used a 2 bolt flange on a 3" opening. Big hole for 2 bolts to cover. If the issue keeps on I will take it to a local performance shop and have them cut off the 2 bolt flanges and weld in some 3 bolts. Every time the gasket blew (4 times now) it was out the sides of the gasket.

 

huh strange you guys are having this problem.. though i have the header dp combo.. it's only a 2 bolt and i've not had an issue.. but idk.. and my bolts are fine when all did you guys get your stuff?

 

damn i had the same problem with xtc dp and my gmpp cat back they kept blowing the gaskets out right their pissed me off cause at a crusie in a higher gear you could hear the leak lol

 

ordered mine about 3 months ago and put it on about a month ago

 

huh

weird .
well i hope you get it worked out