Custom Intake Manifold Gasket

[MMcCallie]

I had a custom intake manifold built that is leaking horribly. Brand new head was ported and had the intake manifold cut off. It seems likely the surfaces are very poorly matched and not sealing well, I'll deal with that once we get it all apart, hoping the head doesn't have to be resurfaced.

A gasket was used between the head and the manifold that blew on the first test drive at only 42 psi. The engine previously made almost 50 psi with the current single turbo. With the massive air leaks I can get only a very hot 31 psi.

By pressure testing from between the turbo and intercooler, we've been able to feel the massive leaks by hand, largely on the underside behind the P7100 pump. We'll have to make a custom gasket, hopefully one that will never let go.

What sort of gasket material should be used that will hold without fail? I'm guessing I'll want it to hold to at least 200 psi to make sure it will hold at my levels. Probably have to have at least one thin layer of steel with some sort of coating, possibly interlaced with metal fibers? I know the gasket needs to be thin but it may have to be thicker to compress and plug possibly wide gaps. I'll post in the 12 valve forum as well.

Does anyone know what type and where I can get a big sheet of gasket material for this application?

Thanks,
Matt