soften old exhaust gaskets for reuse

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22 Dec 2009 04:03 #340241 by saltydog
soften old exhaust gaskets for reuse was created by saltydog
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

1981 KZ1000 CSR, 1982 KZ440 ltd, 1972 Honda ct90, 1978 KZ 650

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04 Feb 2010 16:54 #346489 by Jeff.Saunders
Replied by Jeff.Saunders on topic soften old exhaust gaskets for reuse
Copper exhaust gaskets are hollow - annealing them doesn't make them hollow again.

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

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04 Feb 2010 19:15 #346535 by saltydog
Replied by saltydog on topic soften old exhaust gaskets for reuse
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.

1981 KZ1000 CSR, 1982 KZ440 ltd, 1972 Honda ct90, 1978 KZ 650

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05 Feb 2010 04:45 - 05 Feb 2010 07:26 #346571 by Jeff.Saunders
Replied by Jeff.Saunders on topic soften old exhaust gaskets for reuse
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.

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Last edit: 05 Feb 2010 07:26 by Jeff.Saunders.

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05 Feb 2010 04:53 #346574 by Old Man Rock
Replied by Old Man Rock on topic soften old exhaust gaskets for reuse
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

1976 KZ900-A4
MTC 1075cc.
Camshafts: Kawi GPZ-1100 .375 lift
Head: P&P via Larry Cavanaugh
ZX636 suspension
MIKUNI, RS-34'S...
Kerker 4-1, 1.5" comp baffle.
Dyna-S E.I.
Earls 10 row Oil Cooler
Acewell 2802 Series Speedo/Tach
Innovate LC1 Wideband 02 AFR meter

Phoenix, Az

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05 Feb 2010 05:30 #346585 by otakar
Replied by otakar on topic soften old exhaust gaskets for reuse
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.

74 Z1-A stock
76 KZ-900 Totaly stock vice MAC pipe
77 KZ-1000A stock
78 Z1-R 100%MINT 500 original Mi.
78 Z1-R Yoshi 1103 kit stage 1 cams Yoshi pipe. Etc
79 KZ-1300 (1400)
80 KZ-1300
81 Scratch built GPz1150R
82 KZ1000

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05 Feb 2010 08:56 #346634 by kzr750r1
Replied by kzr750r1 on topic soften old exhaust gaskets for reuse
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.

KZ750R1 + 1991 ZR750 = KZR750R1
Better to be shot out of a cannon then squeezed through a tube. - HST

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05 Feb 2010 18:31 #346751 by sbc1320
Replied by sbc1320 on topic soften old exhaust gaskets for reuse
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.

1980 KZ1000 LTD-B4(MK II engine) - Progressive suspension, MTC pistons, Dynojet Stage III, all wear items replaced, WFO paint scheme(1978), etc..

Past bikes- 2 1976 Kz900's, 5 1975-76 Honda CB750's, Honda 500 -4, Honda 250, Honda 125, Honda 100, Suzuki RM 250, Honda XL350, Kawasaki KLR 650, etc..

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05 Feb 2010 18:48 #346753 by PLUMMEN
Replied by PLUMMEN on topic soften old exhaust gaskets for reuse
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 B)

Still recovering,some days are better than others.

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05 Feb 2010 18:50 #346754 by PLUMMEN
Replied by PLUMMEN on topic soften old exhaust gaskets for reuse
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? ;)

Still recovering,some days are better than others.

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05 Feb 2010 21:32 #346778 by Visayanrider
Replied by Visayanrider on topic soften old exhaust gaskets for reuse
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)

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06 Feb 2010 00:04 #346785 by Patton
Replied by Patton on topic soften old exhaust gaskets for reuse
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! :)

1973 Z1
KZ900 LTD

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