How to Make Gaskets for Engine Parts and Related Mechanical Equipment

Last Updated: July 23, 2017

If a replacement gasket is not available for your application (obsolete, etc.) or it is too expensive or you don't want to spend the time chasing it down at a store, then learn to make your own with a sheet of gasket material and some simple tools and tips.

Steps

1
Clean the mating surfaces with a scraper. With aluminum or soft metals, take care not to mar them.
- Avoid letting the debris fall into the cavity.
2
Cut/tear a patch of typical brown grocery bag paper large enough to cover the gasket area.
3
Hold the paper patch firmly on one mating surface with one hand. Use a finger or thumb of the other hand to press the paper along all the edges and bolt holes of the metal surface making an imprint on the paper. Take care to keep the paper taut over the surface free of wrinkles, and do not let it move.
4
Use an X-acto knife (or similar) to cut out the paper along the lines imprinted on it.
5
Lay your paper pattern on the sheet of gasket material (cork sheet, Fel Pro Karropak or what have you). Hold it firmly while you trace out the gasket using your paper pattern and a pencil.
6
Use scissors and/or your X-acto knife to cut out the gasket from the sheet of material. It is very helpful to use a hole punch to create the bolt holes in the material.
7
Complete your project. With your homemade gasket, things should go smoothly!