Thread: Sanding/Leveling Ebay Exhaust Flanges -- What to Use?

Hey,

My header to downpipe connection on my Ebay exhaust kit(for my 2000 N/A SE) is very uneven (Thanks China!). What would be the easiest and cheapest way to sand or level out the two flanges so they match up better? What tools are needed and how would you go about it? I'm tired of the exhaust leak caused by the uneven connection!

Thanks!!!!

if you want to lap the flange flat you need a glass table, some 200 grit sand paper, some tape, and some water.

tape the sand paper to the glass table (or any other completely flat surface, an lexan sheet will work as well, add some water to the sand paper so that they last a little longer, then get to breaking the shit out of your arms rubbing that flange back and forth across the paper. you don't need to exert too much pressure as that will ruin your sand paper. take it nice and easy and in about an hour you will have a perfectly flat flange. this basic method can be used to lap any object completely flat.

or...

a copper gasket should seal up unless its really really uneven.

I'm using a copper gasket and the gasket it came with. Still doesn't seal.

Is there a power tool that can do the sanding? I tried a method similar to what you suggest, but didn't get too far, the steel they use is pretty hard stuff.

Combination 4" x 36" Belt / 6" Disc Sander

that should do it.

B13 Rallycross prep on a budget - Page 3 - SR20 Forum

This guy posted up having to use a belt grinder. Good build thread to read up on.

Seems like I can convert my angle grinder into a sander...looks like that'll be the easiest/cheapest route.

good luck with that. maybe you can get it clamped up in a vice to act as your straight edge when grinding, or clamp the angle grinder so you can make a 90 to make it flat.