copper exhaust gaskets

I have a TIV and I am replacing the copper exhaust gaskets, but the #3 cyl will not come out. I have asked nicely, I have probed, I have stuck, jabbed and forced an attempt... still won't go. I use a screw driver, I made my own pry bar with an old flat drill bit and bent it to a 90o. I am going to use a pen torch next and heat it up... unless someone can give me a better suggestion? I am not even sure if the TI's use them, but I could certainly use some advice.

No help here. Was that one of the replacement coppers?

Sears sells a seal removal tool that might do the job.

Looks like a claw hammer head, but is only about 1/8" thick (it's a stamped piece of sheetmetal with a nice vinyl handle).

Look for it in the automotive tools department at Sears. Hook the toothed end under the inside lip of the gasket and simply pry it out.

that is like the tool that I made, however, the gasket is sealed and there is no gap to pry between. This is one of the old gaskets that I have not been able to make progress with. The passenger side is done and I would be rolling if I could get this one out. How much heat (I know that it is an exhaust port) but how much direct heat can I direct to the opening without the worry of screwing something up?

another quick dumb question... how hot do the exhaust headers get? Over 500o? under 1000o? right out of the valves?

I feel your pain. Been there, done that. Can't really offer much. Mine eventually came out by totally deforming it with a screwdriver and then bending the hell out of it until it just fell out. The secret was to get any kind of an opening to insert a pry tool. Sounds like you've all ready been there. Presevrance will reward you.

I sometimes think VWs are like Zen masters, they teach you disciplines by testing you. When you succeed, you are a stronger person. NO, I have NOT read, "Zen and the art of motorcycle maintainance".

Kevin 1 - speedster 0. I won this battle. It took me three days plus, but I did it. David I essentially did what you said. I got a flathead screwdriver and I repeatedly jabbed and twisted. Finally it wore through and broke and I was able to get a pair of needle nose vise grips on it and yankee it out.

Now on to the build and hopefully be driving this weekend instead of pissin and moanin!

WOO-HOO!

od, let me know if your interested in a drive this weekend. I should be able to get a kitchen pass.

If I can get it out of the garage, I will be up for it. But I still have some time putting everything back together and I was planning on doing that on Saturday. Sunday is the last soccer game of the season, so that is out.

Odwagerty, that's encouraging news about being able to finish your rebuild. When you fire that bad-boy back up, rev the engine a couple of good hard blips through those twin glass-packs for us!!

Drive it like you stole it and keep the rubber side down!

Remember, when putting in new copper gaskets, they are not going to fit perfect either. Test fit each one individually, squeeze, bend, and deform until each one is a perfect fit. If they go in crooked, they may or may not seal, but for sure they will be hell to get out next time. Preservere!

david, you were right again about the copper gasket not fitting right out of the box. I swore at first the gaskets that I had were not for my engine. The #2 went in like Errol Flynn, but the other needed a little convincing. I told them (with a few gentle taps of bp hammer) that they would have a better life in the #1 3 and 4 port holes, they jumped on it. The passenger side is back firing every so often, so I must not have seeded one or both of them in properly? Either that or the carb has come loose and I am getting air in the intake mani.

Any who, I got it running today and although it is throaty as all hell, I think that I like it. I left room in case I want to add a muffler later on, but for right now I just have to find the right tail pipe. I have tempos on there now.

here is a video shot today.


http://www.youtube.com/watch?v=DoqCjErdns0

COOL!!