UPDATED>>>>>>>READ BELOW!


Today I went and installed my new DC Sports header 4-2-1 1 piece, even bought a new o2 sensor. Everything went fine until, I went to bolt up the bottom flange to the cat. It wouldnt go all the way together the two metal flange things where apart and it needed to be pushed together problly another 1/4 of an inch give or take a little. Anyways I cranked up my car and sounded like a pissed of bumble bee. I could hear the exhast leaking from that exact spot. Didnt sound good either. Anyone got any ideas? Would I have to take it to a muffler shop and hopefully they can fix it? Please help I dont want to sound like a ricer



Modified by megaman096 at 4:32 AM 5/18/2006

 

yes you will ahve to take it to a muffler shop shouldnt be more the $35 or so

 

Do you have the donut gasket in there? Should be a donut gasket between the header flange and the b-pipe.

 

donut gasket? DC didnt provide me with one.....

 

Is it on my old header? help me guys I really would like to fix it myself

 

DC does not include a new donut gasket. There is one on your old manifold, but I'd suggest buying a new one at your local dealer. Also, make sure you reinstalled the metal gasket that goes between the header flange and the head.

 

ive had this problem with the itr header cause its got a 2.5 inch flange that damn donut gasket haha

 

Do I just take a pair of pliers and rip the donut gasket off and slap it on the dc sports? DC didnt say anything about this in the instructions.


Modified by megaman096 at 9:03 PM 5/16/2006

 

usually cars have a flex pipe, but older Hondas have a donut gasket when the engine flexes the exhaust from torque ( ). Thats why you need it.

 

Or just take a flat head screw driver and pry it out. it should just pop out. But you do need this gasket, as well as the one going between the head and the header.

 

i got the one going between the head and the header on there, cleaned it up very carefully. Alright I will try it tomorrow, well I am going to go outside right now and pry off donut gasket. DC should really have told me this, lol.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by megaman096 &raquo;</TD></TR><TR><TD CLASS="quote">DC should really have told me this, lol.</TD></TR></TABLE>

I'm almost positive it's mentioned in the instructions, at least is was in the instructions that came with my DC headers in the past.

 

I can vouche for megaman here, DC doesn't say **** about the donut. I installed my 4-1 and attempted to use a new donut gasket from my local dealer. Damn thing didn't fit!

 

+=

 

If you have trouble getting the donut gasket to fit, I used one from a GSR, it's a little bigger so it fits the DC header better.

 

Great info, do you guys happen to know if the donut size is the same for an EX/Si exhaust manifold and a CX exhaust manifold. If not I might go and pick up one for a GSR.

 

DUDE, YOUR MISSING THE DONUT. PULL IT OFF YOUR STOCK ONE

 

i went and bought a new donut gasket and thew it on my header( the old one looked like total ****). Yet were it meets the cat the top part meets closer than the bottom part /\ kinda like that but not as drastic but noticeable. When I get at 2500 rpms in 2 and 3 i hear a little buzzing noise then goes away at about 3000. I dont think it is sealing good on that underside part. If only dc would have angled the bottom part of my header up a little bit more I guess. Anyone got an idea of what to do? Maybe some sort of high temp gasket sealer? I am very VERY picky about my car.

 

bump

 

It is designed to flex which is why it has bolts and springs on it. It is hard to get it straight but not that hard. I would take the cat off and keep trying till you get it.

 

As for the sealant I dont think that will work.

 

ya loosen up the bolts for the cat and try tightening from the header and work ur wak backwarks towards teh rear of the car. that way everything should fall into place a bit easier cause the donut gasket side doesnt have to be dead on like the other parts

 

alright so there are some bolts that are behind the cat on the muffler side of the car? I didnt get back that far to look but I will when I get a chance again. So heres what I should do. Take off the bolts to the header, then remove the cat from the back side, then it should be removed from the exhaust. Take the cat back up and put it on the header straight. Then take the back end of the cat and mount it onto the existing exhaust. BUT wouldnt it make the backside not align up? Maybe? Maybe not? Anyways I appreciate everyones help, this site is awesome.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by CRXified &raquo;</TD></TR><TR><TD CLASS="quote">ya loosen up the bolts for the cat and try tightening from the header and work ur wak backwarks towards teh rear of the car. that way everything should fall into place a bit easier cause the donut gasket side doesnt have to be dead on like the other parts</TD></TR></TABLE>

He is right I had this same issue with one of my friend's car that I was installing the same headder on. Start from behind the Cat, then move foward. The donut gasket will seal more as you tighten the bolts. Good luck!!

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by ****** &raquo;</TD></TR><TR><TD CLASS="quote">Do you have the donut gasket in there? Should be a donut gasket between the header flange and the b-pipe.</TD></TR></TABLE>

yep i had the same problem bro...i forgot to put the donut gasket back on...just did it yesterday...