A new exhaust system is one of the smartest moves anyone can make to improve their vehicle’s power and performance. And the gaskets used to seal the system are just as important as the big-ticket collectors, tubes and mufflers that it’s made up of. Exhaust system gaskets may not enjoy the high-polished prestige that other exhaust components do, but they’re responsible for much more than simply keeping engine noise to a minimum, or preventing unchecked gases from escaping into the atmosphere.
Gaskets perform the critical fine tuning and pressure equalisation that’s necessary for efficient exhaust scavenging. That means anyone who’s looking to get the fullest benefit from an exhaust upgrade also needs to be sure that the gaskets they’re using are properly suited for their intended level of performance.
Get Perfect Static Fit from Premium Exhaust Gaskets

Make no mistake: while there’s no shortage of variables to consider when it comes to upgrading an exhaust system, there’s also no getting around the fact that upgrading to high-performance exhaust gaskets has to be a priority. High-performance gaskets are essential for preventing exhaust gas from escaping the system under conditions that involve extreme pressures, severe vibration and high rates of expansion and contraction.
And as unremarkable as they may seem, their varying gauges and thicknesses are ultimately responsible for how stably an engine produces power, its fuel consumption and even its long term reliability. At their most basic, exhaust system gaskets are designed to fill the spaces between engine blocks and exhaust manifold mating surfaces, and the flange gaps between exhaust tube sections.
And it’s their static but imperfect fit that gives them the heat- and vibration-resistant edge when it comes to:
- Preventing exhaust leaks. The exhaust gaskets are designed to conform to the irregularities that exist between high temperature mating surfaces, making them the first line of prevention against hazardous fumes being leaked into the atmosphere.
- Improving engine efficiency. The exhaust systems need to be able to efficiently scavenge spent gases in order to produce power, and exhaust gasket seals are crucial for providing a fully pressurised environment that supports maximum low pressure exhaust gas evacuation.
- Minimising exhaust noise. The exhaust gaskets are integral to minimising unwanted exhaust noise and resonances that can end up either being directed back into the vehicle, or attracting unwanted attention from local law enforcement.
- Protecting engine components. The heat resistant properties of high-performance exhaust gaskets help prevent heat from escaping from the exhaust system and creating problems for catalytic converters, emissions sensors, and other thermally sensitive automotive electronics.
- Reducing excess heat buildup. Not only do the heat resistant properties in exhaust gaskets help protect engine components from heat related problems, they also prevent excess heat and exhaust fumes from migrating into the passenger compartment.
While the mechanical advantages of premium quality exhaust gasket and flange sets are impossible to ignore, their core benefit still comes from metal-on-metal cushioning. Whether it’s on a low compression turbo-diesel 4×4, or a high compression fuel-injected sport sedan, gaskets are irreplaceable at preventing exhaust system fatigue, and ultimately premature parts failures due to heat cycling. And not surprisingly, the job they perform is surpassed only by the durability of the materials they’re constructed from.
Durable Exhaust Gasket Compositions That are Built for Performance
From the tensile, donut-style gaskets used on catalytic converter, muffler and flexi-pipe exhaust flanges, to the severe duty copper-composite gaskets used on high-performance engine manifolds, the structure and characteristics of the materials used to manufacture exhaust gaskets are anything but ordinary.
Superior heat and abrasion tolerance, and the ability to resist deformation, even when compressed between dissimilar metals (known as low creep relaxation), are all essential attributes for exhaust gaskets. It effectively means that the materials they’re constructed from has to be tougher than the exhaust tubes themselves.
With their premium selection of high-performance qualities, exhaust gaskets are available in a range of materials that include:
- Graphite composite. Steel reinforced graphite composite exhaust gaskets are known for their light weight, thermal conductivity, and excellent seal retention to 650⁰C, making them the perfect choice for multiple reuse exhaust flange joints without a significant loss of sealing capacity.
- Multi-layer steel (MLS). MLS exhaust gaskets are constructed of multiple layers of corrosion-resistant carbon or spring steel, sealed with a heat resistant outer layer of nitrile butadiene (NBR) or fluoroelastomer (FKM) rubber, and are ideal for evenly distributed torque applications like between engine heads and exhaust manifolds.
- Multi-layer steel with a molybdenum disulfide (MoS2) coating. With an MoS2 chemical coating, MLS exhaust gaskets have even greater tensile strength and lubricating properties that help them perform better in high-temperature, high-load environments.
- Ceramic coated. Although used primarily in industrial engines and firing applications, ceramic coated exhaust gaskets are designed to withstand operating temperatures to 1600⁰C, and feature excellent thermal and corrosion resistance.
- Sandwiched alloys. Sandwich type gaskets are closed-edge gaskets typically comprised of two thin layers of steel, aluminium, or copper with a graphite core, and are excellent for use in high-temperature and high-pressure environments.
With the heavy duty, reinforced compositions used to make modern exhaust gaskets, engines are capable of higher outputs, and are quieter and more thermally efficient than ever. It’s also from the operational standpoint, however, that compatibility becomes the greatest concern.
The stability, heat tolerance, and durability of an off road 4×4 exhaust system is inherently different from what’s needed by a supercharged sports car. That’s why it’s important to understand precisely which exhaust attributes an engine has before settling on any specific set of gaskets.
Exhaust Gasket Compatibility is the Key to Engine Reliability
There are literally hundreds of exhaust gasket choices and kits on the market for every type of engine combination. Make no mistake, though: each one carries a reminder of how an insufficiently rated kit can quickly end up costing more than a few demerits for vehicle noise and emissions.
At their worst, an incompatible gasket combination can lead to premature engine failure, which is why when installing new exhaust systems owners have to careful of the following:
- Heat resistance and low creep relaxation rates. Not only do exhaust gaskets need to be able to withstand engine heat cycling, they also need to be able to maintain the required thickness and load bear capacity when sandwiched, or tightened down between dissimilar metals.
- Compatibility with the correct engine type and output. If an engine has been clearanced, undergone significant exhaust port work, or is producing more power than delivered from the factory, owners need to be sure that their exhaust gaskets have the size and tensile strength to match the increase in heat, output, and tensile load that they’re likely to be exposed to.
- External factors like expected lifespan and reliability. While every owner expects to get the longest possible service life from all of their gaskets, the gaskets employed where corrosive exhaust gases are most likely to be compounded by harsh environmental conditions need to be even tougher than ordinary sealers.
All of these factors have to be considered to get the fullest benefit of a gasket kit. With the proper attributes, however, they can be configured to reliably satisfy any engine/exhaust system combination, regardless of the operating conditions.
The Final Word

At the end of the day, an engine is only as reliable as the parts it’s constructed from. And nowhere is this more vividly illustrated than with the exhaust system, where relying on insufficiently rated gaskets can bring even the toughest engines to a standstill. Whether it’s on a simple exhaust system upgrade, or a complete engine rebuild, high-performance gaskets are the key to ensuring reliable engine performance. They’re an investment that’s well worth making.