How To Make Custom Exhaust Gaskets For Your Special Project

Exhaust gaskets are a pain, no matter how you slice it. When you have a leaky manifold, header, or flange gasket, all you hear is that annoying “tick tick tick tick tick” whenever you are driving. Replacing the gasket is not that hard, the right gasket is the key to the entire job. Most of the time, you can roll up to your local NAPA Auto Parts Store and pick up the exact right gasket for your car for just a few bucks, but what if your ride is a 1929 Pierce Arrow? Unless you have a time machine, you are probably stuck with that ticking sound. Oh wait, you do have a time machine, and it is called Fel-Pro Proramic 101. Now you can make custom exhaust gaskets for any application.

Fel-Pro Proramic is a must-have for every DIY mechanic that has to work on non-standard engines that need gaskets. Most gaskets are die-cut to specific shapes and sizes from cork, silicone, or paper materials, but this stuff doesn’t last more than a few minutes in an exhaust system. While many new vehicles use multi-layer steel gaskets, anything older than the mid-2000s (and some newer cars too) use gaskets made high-heat resistant materials with a steel core. The two halves are bonded to the steel core, which keeps the gasket from blowing out, keeping your exhaust in the pipes where it supposed to be.

Making your own custom exhaust gaskets is not difficult, and this process works on standard gasket materials as well. Non-steel lined material is much easier to work with because you don’t have to cut through the steel core, but we made the gaskets shown here with relative ease. You need two tools that you might not have on hand—tin snips (you should have at least one pair of these), and either a set of hole punches or a hole punch tool. Our punches came in a set of six, and while you won’t use them often, when you need them, you will be glad you spent the money on them.

We picked a sheet of ProRamic 101 and got started. First, the material was placed on the bench and we traced the shape of the gasket with a pencil.

Next, we used a punch that was the closest to the require hole size and made the holes. A couple of blows with a hammer cut right through the gaskets without any tearing or jagged edges.

Then we used a pair of tin snips to carefully cut out the outside shape. Cut slow and careful. The metal core can cut, so be careful.  

We used the hole punch to get the center hole started, then used the snips to finish the job.

Now we have a pair of custom-made exhaust gaskets that will last many years of reliable service. So the time your ’29 Pierce Arrow (or any number of internal combustion engine) needs custom exhaust gaskets, you can make them yourself.

Check out all the exhaust parts available on NAPA Online or trust one of our 17,000 NAPA AutoCare locations for routine maintenance and repairs. For more information on how to make custom exhaust gaskets, chat with a knowledgeable expert at your local NAPA AUTO PARTS store.