soften old exhaust gaskets for reuse

Some of you may already be aware of this process, but this is what you should do to soften your old copper exhaust gaskets, before you reuse them, so that they will seal better.

link.brightcove.com/services/player/bcpi...45&bctid=57437956001

Copper exhaust gaskets are hollow - annealing them doesn't make them hollow again.

Annealing is worth while on copper washers and copper head gaskets.

I have to disagree in that they are made softer where they will conform better than if they were left hard. It is handy when you are not near the exhaust washer store. I have never had one leak after anealing them. New,would of course,be better.

If you want to break an exhaust stud reuse them.... it's a foolish saving.

I'm as cheap as anyone else reusing what I can. I NEVER, EVER reuse exhaust gaskets. The first time you break an exhaust stud, your opinion will change immediately.

Do a search on broken exhaust studs on this forum - most of those sheered off studs are people overtightening the exhaust nuts trying to eliminate an exhaust leak the wrong way.

The hollow design crushes down and conforms to the space WITHOUT any significant torque on the exhaust stud.

Plum taught me something I hadn't realized in this concept, also depends on the exhaust gasket itself... In review of the gasket from a side profile, see if it has a line (such as 2 piece split line) running around the outside diameter...

These are one time use, throw away for the process won't work out right thus exhaust leaks... If solid, no line, then can go this route with a fair amount of confidence...

Same time, I'm totally with Jeff on this one for as cheap as these copper gaskets are, why bother... Tight seal every time thus no ticky-ticky exhaust leak sound...

Just a thought...

OMR

They are so cheap, why would I want to mess with them. I usually have about 20 on hand at all times. I agree with Jeff. Every one I have ever seen was a hollow tube/ring. I am not risking snapping a exhaust stud due to thermal expansion and a over-compressed gasket. Just not worth it. Every time I am down to less than 10 gaskets i just order more.

Had not thought about the over tork issue and breaking studs. Glad I have a spare set for my next round of maintenance.

Thanks guys.

I was thinking that the gaskets with the seam have like an asbestos ring or gasket inbetween the copper. My bike had 2 solid gaskets in each port.

some copper gaskets are actually one piece,maybe yamaha or some place cant remember what they come off of.anywayway if they are made like a washer they could be heated up and cooled to reuse them.the vast majority of them are the crimped copper things which i wouldnt bother trying to reuse.and remember if ya spray some copper coat on the crimped side it holds them against the head better while installing exhuast and dont forget rubber bands on split collars to hold em in place

sbc1320 wrote:

I was thinking that the gaskets with the seam have like an asbestos ring or gasket inbetween the copper. My bike had 2 solid gaskets in each port.

they either forgot the old ones or something wasnt sitting square requiring 2 in each?

We're lucky to have a guy like Jeff from Z1 to help with an issue like this, what he says goes! (especially on this one)

Before reinstalling headers, remember to double-check each exhaust port for a second old crushed gasket inside the port, which could be difficult to notice. A dental pick style tool is handy for this inspection.

It's not unheard of for someone to use two old crushed gaskets instead of a single new gasket.

Good Luck!