03-28-2015, 01:01 PM
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#1
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GX Member
Join Date: Dec 2014
Location: Illinois
Posts: 35
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Tsudo 4-2-1 Fix.
I noticed alot of people have problems with the Tsudo 4-2-1 header for the 2.2l Ecotec, I myself have tried to fix it so many times i almost just switched to Pacesetter. I noticed the last time that i took the header off that it seems to be the widest diameter right up at the flange.
I measured both inner diameters and also found that the ID of the header was 2" exact and the inlet ID of the down pipe was 2 1/8". I cut some pipes and used a lathe to taper the end and welded them on.
I welded all the way around both. The idea was for the new pipes to fit in the down pipe and almost eliminate the need for a gasket there in general. After grinding down a couple high spots on the welds i put the two together and it fit perfectly. I cut a new gasket to play it safe.
Everything seals great and and i have no leaks what so ever. I drove the car for a few hours and tightened the bolts again and did the same the very next day.
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03-28-2015, 01:12 PM
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#2
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GLS member
Join Date: Aug 2010
Location: indy
Posts: 8,411
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Nice work
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03-28-2015, 01:48 PM
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#3
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GX Member
Join Date: Dec 2014
Location: Illinois
Posts: 35
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Thanks man, I hope this could help some of the other people struggling with that damn flange blowing out gaskets.
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03-28-2015, 02:58 PM
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#4
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OSV coming soon!!!!!
Join Date: Jun 2006
Location: lindsay, ontario
Posts: 2,375
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Is the gasket metal as well? I'm just thinking, now you know these dimensions, would it be possible to weld the flares on that gasket to go inside the header? You could make them and sell them as a fix and make a bit of money on the side.... I'm not sure if it's possible at all but thought I'd mention it...  good work man!
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03-28-2015, 04:30 PM
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#5
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Premier V.I.P. Member
Join Date: May 2011
Location: Ferdinand Indiana
Posts: 2,742
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Good stuff. 
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3rd alero- 02 GX 2.2 5sp coupe. drove for 3 years 55,000 miles. Sold for a kids first car, and missed
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03-29-2015, 11:49 AM
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#6
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GX Member
Join Date: Dec 2014
Location: Illinois
Posts: 35
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The pipe actually goes into the down pipe by about 1/8" with the gasket and without the gasket its just about 1/4". Its a metal gasket with some sort of fiber surrounding it. I got the idea from a donut style gasket when i was doing some work for one of my buddys. I'll have to experiment with a welded gasket style sometime. Something you could just slide in and bolt on would probably sell a few at least lol.
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Last edited by WreckItRoth : 03-29-2015 at 12:29 PM.
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03-29-2015, 04:01 PM
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#7
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OSV coming soon!!!!!
Join Date: Jun 2006
Location: lindsay, ontario
Posts: 2,375
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That's what i was thinking especially if it's a common problem... and given by the pictures above you have some skills to attempt it haha!
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Misty: 3400, S&S headers, TCE 65mm TB, CAI, 180* TStat, Milzy motor & tranny mount, 18" BOSS 328 & much more... going osv!!
Silver: 2.4L, 5 speed, GAGT seats, front & rear STB's, all red tails, led headlights, Magnaflow muffler, Milzy Motor mount, WAI, Cosmo short shifter; sold n missed
Tequila: 2.4L, GA interior swap, scrapped...
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04-08-2015, 01:50 AM
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#8
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GX Member
Join Date: Dec 2014
Location: Illinois
Posts: 35
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Next time i can get access to the machine shop i will definitely give this idea a shot. And thanks man!
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04-08-2015, 07:59 PM
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#9
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Aleromod part owner
Join Date: Nov 2003
Location: Far Northeast Philadelphia, PA
Posts: 18,199
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Nice work 
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2000 Olds Alero 3400 SFI 14.53 @ 94.93
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