Anybody ever have this problem before? Been through two sets of paper gaskets and one set of aluminum gaskets now. They break and fall out, truck sounds like **** when it happens.

 

Maybe time for a ball and socket (gasketless) flange kit??

 

This will fix the problem and a lot cheaper than the Flowmaster flanges.

http://www.headerbuddy.com/headerbuddy.html

 

Good link, thanks! I will look at it more tomorrow when I am more awake. I take it this is a common problem?

I just finished changing the gaskets. Here are some pics of what's left of the set that lasted one week exactly. It almost looks like they melted through and they sprayed metal particles all over the front driveshaft and tranny heat shield.

 

On my old Nova, I used to use some Hi-Temp orange Permatex on both sides of the gaskets and that would help them a little longer.

 

Are your cats cloged?

 

This might sound crazy but try using antisezie with no gasket. I was told to do this on all of the flanges on my truck including the turbo flange and it works.

 

From what ive read that if your not useing the ball and socket flanges , the best gaskets are the copper gaskets .

You can pick them up from Summitt for about $10 bucks and they work great .

Thats what im useing and havent had any blow out yet !

 

I'm in agreement with the copper gaskets. I'd try those first. It is pretty obvious that the heat in front of the cats is higher than the melting point of aluminum. It would be very difficult to install those header buddies considering your flange is so close to the cat. Also make sure you have good lock nuts on those things. Don't use the ones with nylon in them obviously.

 

Red RTV works really Good
I ran it on all of the surfaces where things meet up
just make sure things are nice and clean and tighten things up nice
Btw this is on a turbo setup too so there is some flow going on