I saw something on TV once (Trucks maybe?) that I'd like to try. They're a heavy duty clamp for collectors. Each side is 3 pieces to form the triangle and it looks to be about 1/2" or thicker. Looks like it would work but I can't remember the name of the company that makes them.
It's an often fought battle that can be won. Get the best quality gasket you can find, stay away from the crappy paper type ones. One of the reasons leaks begin with headers is from the stresses of the engines movement and the exhaust resisting that movement.
Adding a stainless steel flex section like the one shown in the pic below to the exhaust head pipes will reduce those stresses and therby extend gasket life...not to mention less frequent tightening of the header bolts.
Although a bit messy you can also coat the gaskets with muffler cement to help with sealing.
Whatever TTI sent with mine held up for a year and a half with a few removals in that time while I was figuring what muffler to get. Of course it didn't have a brand name on it.:doubt:
I used some of the thick Aluminum (sp?) gaskets available from Advance auto with my last set and had no leaks for quite awhile. in fact I sold the car and they were still on it. Used the same aluminum gaskets for the head side and they worked good too!!
I too, have the dead soft aluminum ones ones my ole beater truck, and have had good luck with them.. They really can't burn out like the paper ones (well maybe if your exhaust temps are REALLY high...)
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