BECAUSE THAT'S ALL I SEE lol... The Disco has been sounding like a diesel lately so took the entire system apart, sanded and cleaned up every mating surface, reinstalled and I still have so many damn bubbles pouring out of it.

I assembled the manifolds first (zero leaks head to manifold), then the Y-pipe. Then I separately assembled the tailpipe to the mid pipe, and then then married both assemblies at that flange. All torqued to spec. Is this system just always going to be this way?


Input

Tailpipe to midpipe

Midpipe to Y pipe

Y pipe to manifold (other side looks similar)

 

Assume you used new gaskets at each point? I like to use the Remflex off Amazon at the connection to the exhaust manifold (they are 4x as thick and soft) and coat the rest with red silicone. Install, tighten bolts finger tight so the silicone just touches both surfaces and then let it cure 24 hrs before torqueing. Be careful on the studs in the manifolds, they are known to be very soft, might want to consider these: https://extinctmotorsports.com/exhaust-studs

 

New gaskets, yep. I tried those Remflex gaskets, and maybe I just got a bad batch, but after about 10K miles it just grenaded itself on a drive and sent gasket chunks all over the engine bay, down the Y-pipe, while driving. Went back to the stock gaskets after that. Even torqued them to the lower spec Remflex recommends on the packaging.

And yeah! Got a set of those studs to swap in when the OEM ones inevitably go bad. Thanks for those!

Is it really even possible to have this thing fully sealed up (no bubbles) when stone cold? I'll note that the tailpipe flange is clean though has pitting on the surface. Should I replace the tail pipe? Like, would it even seal if it's not a perfectly machined surface anymore?

 

Well I would say give the reflex another try and this time put those stainless bolts in and torque them to full new specification. You need to get enough clamping Force to hold the gasket in place. I have had better luck with these gaskets then the factory but if you wanted to use the factory then I suggest you double them up with a layer of silicone on both sides of each gasket. You can do the same further down the exhaust system. I have not had a problem getting airtight exhaust systems.

 

OK so Remflex + 30nm (22ft lbs)?

And any specific rec for the silicone?

 

Only use that torque if you put those stainless studs in, you'll risk breaking the factory weak ones

high temperature red