So I'm putting on new headers and I'm replacing the old exhaust gaskets. I've read good things about the copper exhaust gaskets but has anyone actually used them? Harley is telling me that they leak and that I need to use OEM cone style gasket. Any advice?

 

I have used the novello copper crush seals with v&h big shots, bassani, thunder header and have had no leak issues. and they don't block the exhaust ports on the heads when flange is tighten like the SE ones do.

 

I've used the Novello coppers on a few bikes.

 

Every bike I've ever rebuilt has used copper crush seals (albeit, many were Japanese bikes). I've had no problem with the seals. They work well, but are a one-time use. If you pull the exhaust, you SHOULD replace them (I've reused them once or twice when in a pinch and had no problems).

Now a cone style gasket is a different beast. The cone shape is supposed to help with back pressure and preventing the popping and backfiring out of straight exhaust. Talking to some of the OLD riders, in the 70's and 80's, they didn't have the cone gaskets/inserts. To solve the back pressure problem, they would drill a hole completely through the exhaust (toward the bottom of the header) and install a nut & bolt. Does it work? I don't know know, but they swore by it.