TECH: Making gaskets, cheap and easy

Here is a little tech, on making gaskets.
There is always a situation, when you need a gasket right now, either on the road or while building a car, and you can't either find it, don't have time or refuse to pay stupid money for a silly little gasket.

Go and get some gasket material, they come in different thicknesses and materials (cork, cardboard type stuff etc), get an ***ortment, it's pretty cheap, like $6-7 for a 16"X30" sheet.

Here is an Offy intake manifold, I needed gaskets for.
I cut my material to size, trace the outline and then either cut it with a knife or scissors.

Lay the gasket on the piece


I use a "tiny" hammer, with a round head, to work my way around every, bolt hole/opening, the material will break at the sharp edge.
Hammer "gently" at an angle, don't start using a sledgehammer on your rare speedparts.

I usually start with bolt holes, that will hold your gasket in place while you gently hammer away.


After your done, clean up edges with some sand paper or s****e certain areas, to remove any unwanted dust and debris.
Voila

Real simple, It took 10 minutes to make these two gaskets and cost about $2.

 

Looks like it's a heck of a lot easier than using an exacto knife

 

Simple old school stuff - but really works.

 

I learnt to do this as a first year apprentice 30 years ago and was amazed when I first saw a fitter doing it.
Some tricks I have learnt as well:
Complicated gaskets like the ones between engine cases on motorcycles can be made by cutting some gasket material to the same size as A4 paper, and I have used manila folders for gaskets. Put the paper in a photocopier, put the part on the screen press copy, you now have a perfect print of the gasket to cut out.
The same effect can be achieved by putting a thin smear of grease on the part and using it like an ink stamp.
Brendan

 

Somebody told me that was the purpose of the ball end on a hammer,don't know if thats true or not.

 

Nope, supposedly for "peening" rivets.

 

My Grandfather taught us this as kids in the 50's

Bill

 

I had to make some for my roadster in order it get it to Good Guys the next day. The 300 Buick engine seems to have a gasket not stocked by any supplier so I need to make them. Worked great and car ran like top the next day!

 

And if your really in a bind you can use that trick to make gaskets from cereal boxes. They don't last as long but it can get you off the side of the road. Don't ask me how I know.

 

This method also works for masking tape...if, for instance, you wish a head to be painted right up to the manifold mating area, start by masking the edge of manifold by the hammer method to get the line perfect.

 

Flat br*** hammers work well, you dont get the little peen marks in the steel on sharp edges like you can with a steel hammer.

 

those empty boxes of "wheaties" sure came in handy along the road or after hours for the emergency gasket.

 

that was cool, I'll try that at least I want cut my fingers

 

I used that technique years ago in alabama, and later in Iraq. a lot of old school mechanic stuff seems to be resurfacing over there where parts are not always available...

 

I've got a cheap gasket-punch set to make the holes. They look like a leather hole punch set, and come in their own little storage pouch. Works really well for things like dif gaskets. Sometimes you can't get to the surface that needs a gasket--like a ring gear is in the way, or the shift fork on a trans side cover case.

When I bought the gasket punches, I also bought a cheap small cutting board from the dollar store and keep it with the punches so I always have something to back it up with. Those, and a utility knife, and I've made a lot of gaskets that look like they were punched out of a machine.

Just taught my 13 year old how to make a gasket with these the other day. Getting tougher to impress the teenager, but making a brand new gasket to replace the torn one that was on the trans did the trick. Not having to spend any money or stop work to order the part was found to be really impressive.

-Brad

 

Great post dreadman, this is what the hamb is about to me.

Feel free to share the simple tricks that some of us weren't lucky enough to have taught to us.

Thanks.

 

My dad taught me that trick about 50 years ago ,works well.

 

I can't remember who showed me that trick first, but I've used it a whole bunch.
I even bought a 2 oz. "gasket hammer" specifically for making gaskets. The light hammer lacks the horsepower to do any damage to the edges of the part, as some have mentioned.
The biggest problem I have with that method is that most of the gasket material I've found in parts stores around here is 20 millioin years old, dried out and brittle. You're better off using cereal boxes if that's all that's available.

 

Showed my 20 yr old that trick a few days ago, saved a drive into town.

He already discovered the pocket knife/kleenex box thermostat gasket trick a few years ago

 

gotta second the manila folder option..my file cabinet has taken a beating over the last 15 years,when the nearest parts store is almost a half hour away you learn to improvise.
used to be nice and neat till half the file folders "disappeared"..lol

 

we blew a headgasket in the line to make a p*** at el mirage one time. bob higbee had us pull over instead of losing our spot in line and we pulled the head off. 6 vehicles went by as we made a headgasket out of two pieces of cereal box with tinfoil in between. fired up the bike and ran 128.

 

I always use empty rifle/pistol shell casings to punch clean holes in gaskets. You can buy them new or used at gun shops in all calibers, or if you shoot, just save your empty casings. I have a drawer full in my toolbox of various sizes and use them everytime I make gaskets.

 

My dad taught me this trick years ago when he made a gasket out of a tablet cardboard backing in a pinch.

 

I've been doing this my whole life. (about 50 years workin' on cars etc.). Not long ago I got the wrong gasket for my water inlet to the intake manifold. I just cut the side out of a cereal box and did as described above. Cereal boxes work great.

 

My Dad taught me this one when I was in grade school. Thanks for reminding me of it!

 

Fabricating head gaskets out of cereal boxes and tinfoil; you, sir, are my new hero! That's even better than the episode of Green Acres where they used the remnants of Mrs. Douglas' pancakes to make a head gasket for the old farm truck so Mr. Douglas could get his apples to market.

Instead of using shell casings, why not use a live round? One whack with a hammer and you could blast thru multiple layers of gasket material!

 

Instead of using shell casings, why not use a live round? One whack with a hammer and you could blast thru multiple layers of gasket material![/quote]

Use wad cutters and you won't even have to clean up the holes.