HeeeeeeLP!!!!!
I have an exhaust leak after installing the Evosport headers. I believe its coming from the passenger side downpipe where the headers connect to the exhaust pipe in front of the first set of cats. Ive replaced the header gaskets twice on this side so I am ruling that out. I can smell exhaust from the top of the engine bay on this side only....plus it makes the famous exhaust leak sound. I blocked the exhaust tips with rags but didnt notice any evidence of where the leak was coming from. Shouldnt there be a gasket in-between the downpipe and exhaust piping? The piping in this area doesnt seem to match up very well with the headers with only about 2 MM of seal between the two. Any suggestion? Or experience with this?
PS Didnt get a reply in other thread so I had to start a new one here.
Thanks

Most of the time with aftermarket headers, the downpipes don't match up well to the output flange on the headers. This was almost always the case with Kleeman headers I've seen. When the shop did install those Kleeman headers, they had to cut and re-weld the downpipes where it meets the headers to get a better fit. Another possibilty may be that your headers are cracked. Hope you get it all worked out.

To get a more accurate idea of the location of where the leak is coming from, you can use a stethoscope that has a long thin metal (usually copper) pipe to listen for the leak. Just point the tip in the location of the sound.

another trick is a vaccum hose like from a shop vac or pretty much any such tubing (dont touch the exhaust if its plastic though)

make sure that your evo sport headers are not cracked. mine cracked one after one from time to time.

i have the same issue, but haven't got it fixed yet.

You arent riding around like that are you FranK? If you are, what damage could occur to the motor? Anyone used exhaust putty? Evosport should address this.