I have a set of Downey headers on my 1993 Toyota 4runner with the 3 liter V6 engine. The exhaust manifold gasket has started to leak so I would like to replace it. I called the store where I bought the header a few years ago and they tell me Downey is out of business. I understand the factory exhaust manifold gaskets won't work with these headers. Can anyone suggest where I can get a new gasket or any way to fix the leak?

The gasket has eroded in one spot at one exhaust port and makes a ticking noise when I accelerate. It doesn't seem to have any effect on how the car runs, but the noise is irritating and I can't pass the annual safety inspection. I have tried tightening the bolts on the headers.

the shop manager of the performance machine shop I've used for the past 15 years says that on their race car, they don't even use exhaust gaskets -- he says you just make sure the header flange is machined flat, and they dollop some copper anti-seize on the mating surface and cinch it down.

copper is not the same as the aluminum stuff; it's rated for higher temps.

I'd try that.

what is it about the OEM gaskets that don't work? is there some heat shield material riveted on like on the 22R exhaust gaskets? I just had a similar situation with my DT Header. ended up clipping/grinding the rivets and pulling the heat shield piece off, and it worked out okay, so that may be an option for you as well depending on why the OEM gaskets won't work.

The factory style gasket has some scallops in it. Here is a picture: http://www.rockauto.com/catalog/moreinfo.php?pk=125560

The headers require a gasket that is flat all the way across.

Thanks for the suggestion of high temp sealer. I'll give that a try, if a can't find a gasket.

You would want to pul the headers and have them machined flat if you are going to try not using a gasket. You could cut the scallops out of the oem gasket and use it in sections. If you are using studs it would be easier, if not spray some of the copper gasket spray on them and it should help hold them in place during the installation.

You can also buy high temp composite gasket material and cut out new gaskets. I am not sure how long it will last, the gasket I made for the turbo on my Supra appears to be working, but the Supra is still in its restoration, so there hasn't been much time put on the gasket.

A lot of folks swear by these gaskets. I do not know because I have never used them.

http://catalog.remflex.com/

Those Remflex gaskets sound like just what I need. They have one that will work with my headers too. Thanks!

I installed a Remflex gasket and that has fixed the problem. Thanks to the folks who provided help on this issue.