Cat to Muffler Flange Gasket

[Cali' Explorer]

Hey all. In my never ending quest to get rid of all the 5.0's exhaust leaks, I think I have found the problem. Bad muffler. I've had a new muffler put on, but the gasket that goes from the Cat to the Muffler was too far gone to save.

What I'm wondering is, is there any special, higher end gasket I could use here that would be better than the Ford Parts one. I have literally had this gasket replaced 10 times in the last 6 months and no matter what I do, can't get it to stay sealed.

If someone made a deadsoft aluminum or copper one that would be killer, but I'm guessing I won't have any luck there.

Also, if no one can suggest a different gasket, can you give me any hints on how to better seal it to avoid it coming open again. I am planning on replacing the cast bolts/nuts that are normally used with some Grade 8 nuts/bolts with lock washers (so they don't rust like the stock ones and get stuck and can be tightened easier).

Any help would be greatly appreciated. I would love to do this this weekend if I have time, but I just need all these exhaust leaks gone.

 

[Runnin'OnEmpty]

Steven, you might try your local home improvement store. They should have sheets of copper that you can make your own gasket out of, using the original as a template. While you're there, pick up a couple of stainless steel bolts, nuts, and lockwashers for the flange. It's worth a try......