How do you maintain and clean your exhaust flanges to extend their lifespan?

🚘 Selecting the correct flange type and size is crucial for optimal exhaust system performance. Consider factors such as pipe shape, diameter, clearance, and flexibility needs. Assess the advantages and disadvantages of various flange types: flat, donut, ball and socket, and three-bolt. Ensure proper measurement of bolt pattern and bore size to prevent leaks, misalignment, or pipe stress. Additionally, verify compatibility with your vehicle's make and model. Failure to choose the appropriate flange can result in inefficient sealing and potential system damage.

You are mostly stuck with your flange type you have on your car unless you want to build a custom exhaust system and use proper joining methods. Best off the after market flange types will be a v-band type.

🚗 Regular inspection and replacement of flange gaskets is essential to maintain a secure and efficient exhaust system. These seals endure extreme conditions, making deterioration inevitable over time. Look for visible damage like cracks, burns, or rust, and listen for abnormal sounds indicating leaks. Utilizing a smoke machine aids in leak detection. When replacing gaskets, ensure compatibility with flange type and size. Remember to carefully remove flange bolts and separate pipes during the process. Neglecting gasket maintenance can result in exhaust leaks, noise, and emission issues, compromising vehicle performance and environmental standards.

The gaskets are never made off rubber, rather a steel fibre combination gasket, thin steel or pliable fibre donut depending on the type of flange you use. Best trick for giving any type of gasket a better chance of sealing is to coat it in a thin wet layer of exhaust sealant before inserting it into the join.

⚙️ Regular maintenance of flange bolts is vital for preventing corrosion and ensuring their functionality. Corroded or seized bolts can impede removal or tightening, leading to complications during repairs. Employ wire brushes, penetrating oils, or rust removers to effectively clean bolts. In stubborn cases, heat application via torch or heat gun aids in loosening. Lubricating bolts with anti-seize compound or grease before installation facilitates smooth operation and guards against seizing or galling. Neglecting this upkeep risks bolt breakage or difficulty in disassembly, potentially prolonging repair times and compromising exhaust system integrity.

Using any lubricant on the flange bolts will not be of any help, the bolts together with the rest of the exhaust system reaches very high temperatures and thus using normal grease or anti-seize will be redundant. The best route to follow will be to replace the bolts with stainless steel bolts if it is an option or coat the bolts in a high temperature paint after reinstalling them so that they are protected from the harsh environments that they will see.

After tightening a normal steel exhaust system, I have always fount that to use a high temperature exhaust paint over the joint and bolts do keep them more protected for longer. This will stop the bolts from rusting further.

Maintaining an exhaust flange is a job that very few people do these days as most modern cars come fitted with good quality stainless steel exhaust systems. Most vehicle owners will never even think about this in in the lifetime of their car. I have found that normal stainless steel fasteners work for the normal type of bolted flange joint. That is of course in my country where we do not have slated roads during winter and the only corrosion we see is in costal cities.