Originally posted by Jafro
h: golly.
That's a cast manifold, right? If it is, cast parts break before they'll give. I hope like hell it isn't cracked. If it isn't, get the flange milled. If it is cracked, it's hosed. Look around for a multi-layer exhaust gasket. I've got a 4-layer gasket, and it works great.
You really need to seal off all of your leaks. Intake, and exhaust. I could show you all the seriously blackened engine parts I just pulled off my GSX. I used a 7cm copper turbo gasket that turned to bologna, and squished out of the flanges. 2000 miles later, my whole engine bay (and air filter) were powder coated black... and it was such a tiny leak. Now I'm getting filthy working on it, too.
If you're leaking boost, your turbo loses efficiency and is over-spooling because of it. Basically making no power while doing more work. It's a great way to overheat your bearings and develop shaft play.
Perform a boost leak test. Plug the compressor inlet, pull an intake vacuum line, and blow about 20 PSI into it. If you can hear, but can't find a leak, spray your whole intake down with soapy water and look for bubbles.
Be patient. You're almost there. It's always the little stuff, right?...
no it's not cast iron, it's a tubular 1010 mild steel manifold so it would warp before breaking, at worst i'm thinking the flange would just need to be milled flat again but i bought a thicker gasket with some copper spray today so i'm gonna try that on wednesday. I'm not leaking any boost on the intake side just off the exhaust manifold.