I got a ton of feedback from people on Facebook and IG on what to do to solve this T2 gasket issue. I honestly feel like I've tried everything they've suggested.
One unique suggestion came from Forrest Vert; 100% Silicone Clear caulking from Home Depot. He says it's an old Hot Roder trick he picked up on. Also claims he's been running the same silicone gaskets off the head and t2 flange on his blue SR schassis for years. A few other people suggested it and swear by if.
Alongside all this, my buddy Julio Losh is on his 7th blown t2 gasket. He went and bought the s15 OEM t2 gasket, surfaced the flanges, and copper sprayed everything. I tried that back in June and I only got 2 months out of it.
I decided to take it an extra step and buy inconel studs and stage 8 locking fasteners. I found the kit on Flyin Miatas website! Inconel studs are rated from crygenic temps up to 2200°F (982°C). They should not warp or stretch under high temperatures. With the stage 8 fasteners, the locking washer (held in with an e-clip) will prevent the nut from backing out. I should also be able to reuse the studs and fasteners. The fasteners are fairly cheap but the inconel studs are money.
Since Julio is trying the thicker OEM S15 gasket, I told him the only thing I got to lose is not trying something new. I decided to give the silicone a try.
Below are two photos Forrest Vert sent me of his SR with silicone gaskets.
Here's a few photos From this week's project. I leveled and checked the mating surfaces with a straight edge.
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