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Custom Gasket Manufacturing

With proper tools, you can have straight lines and clean radius on a gasket material. Slimmer pieces of gasket material can be cut using simple gasket cutters and sharp blades. However, custom gasket cutting of materials that are more than a 1/4-inch thick require advanced tools and should be undertaken by a mechanic.
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Place a 1/4-inch thick plywood on an even surface and set the gasket material on top of it. Plywood helps to protect gasket-cutting equipment from becoming damaged. Measure and indicate the final length and width of the material using a paint marker and a steel rule.
Use the straight edge as a guide when cutting along the indicated lines with a utility knife. For a round gasket, mark the center of the rubber material or outline the holes for fasteners on rectangle gaskets using a paint marker. Place the center pin of the gasket material cutter at the indicated center of the material. Undo the thumb screw on the side of the cutter and slide the blade to the edge of the sliced material. Adjust the screw as you apply pressure to the exterior of the gasket material and move the cutter clockwise to cut the round gasket.
Place the hollow gasket cutter parallel to the hole needed in the material. Using a blunt blow mallet, hit the back of the hollow cutter and then pull it from the exterior of the material. Realign the blade with the secured hole and repeat the procedure if the hole fails to come out with the hollow cutter.
How to Install Copper Exhaust Gaskets
• Remove the gasket material from the exhaust.
• Using a clean rag, wipe off the sides of the scraped connection to remove dirt from the exterior of the exhaust link. Place the copper gasket on the working surface and make sure that the material is flat.
• Use a rubber mallet to lightly hit the top of the copper gasket to straighten it.
• Open the copper silicone sealant.
• Place continuous beads of the copper-silicon mixture on all openings in the exhaust connection.
• Place the copper gasket on the exhaust. Adjust the exhaust system to your requirements as you put the gasket in place.
Unlike the usual paper exhaust gaskets, copper gaskets do not become fragile when exposed to heat for prolonged periods. This makes copper gaskets more durable than other types of exhaust gaskets. However, copper gaskets need unique sealants to stick to a car’s exhaust. High temperature copper silicone sealants contract and expand with the copper gasket and remain strong throughout the entire lifetime of the gasket.