Although many racers use RTV to seal headers, Flatout offers various perforated steel core header gasket for effective sealing of different exhaust port shapes. (Photo courtesy Flatout Racing Gaskets)

Sealing the fluids on an engine using copper head gaskets has always been challenging. Thermal expansion rips and tears whatever is on the surface of the copper gasket and then you have a leak. Patrick says he's seen every RTV that can be squeezed from a tube used as a sealant; even Armstrong floor contact cement painted on both sides. More traditional sealing compounds are Hylamar and Copper Coat spray.

Flatout came to market in April of 2001 with a new high temperature polymer sealing material called "Masket" for copper gaskets, and it is unique to their copper gaskets. It is applied to the top and bottom gasket surfaces as an 0.125-inch wide bead that is 0.003-inch tall and routed around the coolant and high-pressure passages. You can buy Masket pre-applied to Flatout's gaskets for an additional $30/gasket pair added to the original gasket pair cost, or purchase is separately for $35/gasket pair.

Flatout recommends this re-torquing procedure for any copper gasket installation. After assembly, they recommend you heat the engine to full operation temperature (without coolant) -- run it for a minute or two. Then let the engine cool to room temperature, and then re-torque - without coolant in the engine. Following the original bolt torquing sequence, crack the first head bolt loose, then tighten it back to the torque spec. Then proceed to the next bolt. Put as much torque into the studs or bolts as recommended by the high quality fastener manufacturer you're using. But also check with the head and block manufacturer for torque value recommendations to make sure you're not exceeding their design limits.

The lifespan of a copper gasket varies according to Patrick, but he notes that a typical copper gasket can seal for a whole season under the proper conditions. High HP engines are typically disassembled more often and may mean renewing gaskets after a few runs. Copper gaskets can be reused on actually the same setup (same engine, same bank) but should be inspected for wear before assembly. The same goes for Masket, which can be reapplied on a used set of gaskets if necessary.

By applying these tips, common sense, and plain old attention to detailed workmanship, you'll be able to seal an engine for success, no matter its brand or configuration.

SOURCES:

Automotive Specialists
Ph: 704-786-0187
www.automotivespecialists.com

Flatout Racing Gaskets
Ph: 877-837-9200 (toll free)
www.flatoutgroup.com

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