…not according to the bubbles… But I will check!
I am wondering if the tolerances are just too tight for a 3rd party fix… Although if have hoped that if you can get the heads in the oval sockets it’s just a case of sealing the join with the gasket…?
The seal face of all 3 header castings should be on the same flat plane before fitting up to the engine. A piece of plate glass can be used to check the 3 ovals touch the glass all around.
Chances are you’ve got some distortion from the welding repair.
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I think I will test this!
Out of interest, here is an image of the seals.
Notice the tags on each side. Might it be relevant whether these are on the bottom face (against the engine surface) or on the top surface (manifold face)?
Either way they need to fold in order for the seal to fit…or are they just manufacturing lugs that should have been sanded off?
Those are the tabs I was talking about, they are just to hold the gasket in place while fitting the headers. Orientation wont matter. If its blowing by the seal I reckon you have an issue with the alignment of the headers as @Col_C said. Doubling up the gaskets may work as a quick bodge fix.
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…i think I’ve just worked out what it was…while listening to Queen, drinking lager and reviewing photos of the job…
Old stud
Close up of new studs
The new ones, bought from Fowler’s…have a shoulder on them…FFS…
They’re the same as mine, and in theory a better design as it gives a positive stop when fitting the studs. It might not be a problem as your originals had a plain unthreaded section too. But to check try feeling with feeler gauges whether there is still space between the stud shoulder and the backs of the header lugs.
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There is, it’s visable!
I think, basically…I got/purchased the “wrong” studs…
What I can’t not fathom…is I would have bought them from Fowler’s/WOT…but, when I search the pages on there…I can’t see these studs! So where/how did I bloomin order them in the first place!?
Anyway, new set ordered with no shoulder this time!
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Final update…new studs ordered …fitted and all back together.
Used some JB gasket maker as well, and all good this time!
Phew!
Bike now just needs a good clean!
I often consider selling and getting something else for about 3k…but I simply wouldn’t think anything will compare. So I choose to love it!
Again, thanks everyone!
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Also, you don’t know what faults are lurking on new-to-you vehicles, whereas at least the one you have you know it’s history and that things have been done ‘correctly’.
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Hi, may I ask who welded/ fixed your headers please? I’m desperately in need of the same on mine 
Hiya, any decent exhaust or fabrication shop should be able to do it, but I specifically got mine done by “rich’s fabrication shop” on FB, he’s in Oxfordshire.
Great job. Great price. Very helpful.
Any fabricator should already know, but make sure headers are well braced so they don’t move/warp from the heat of welding, otherwise difficult to refit.
Good luck!
Thanks DanielB