Fitting collector box-downpipe gaskets

[Athame57]

I've just been through ( for me at least ) the hell of fitting the two downpipes to the collector box of a new system ( from DSS  ) I found it needed me to place the gasket a few inches along the pipe, slip said pipe in to required distance and follow through with the gasket which I had greased of course. The trouble is it is stubborn to the point of it getting some damage.
I noticed a pin hole size gap in the slat on the collector box, courtesy a shortened gasket. I just hope the clamp can take care of that if not I'll be doing the job again. 
Is there a secret or easy way of doing this. I'm aching all over now.

[Athame57]

OK, bought new gaskets to try again.  What I propose to do when the sun comes back out ( I have to work outdoors) is to fit the whole system first ( should make lining things up easier too ) and slide the two down-pipe gaskets in last, this time keeping the outer face grease free by greasing the collector box sleeve instead. The last time I needed so much force I damaged said gaskets. What I probably need is a hack of some kind, does anyone know one?

[taysidedragon]

Fitting the downpipes, collector box and silencer on the 400f has always been a real arm wrestle.
I've got pattern parts on mine with 4 separate downpipes so slightly different to yours. The easiest way I've found to put them on is to loosely assemble the downpipes and collector box off the bike then start fitting the downpipes to the exhaust studs. It's a real ball-ache with the exhaust collets, finned collar and nuts all trying to make a bid for freedom! Leave everything loose then slide on the silencer and get the silencer bracket lined up with the bolt holes on the frame. Then you can start to tighten everything up.
The exhaust gaskets are usually very tight and people often shave them down a bit to make them fit easier. Apart from that I can't really suggest anything else. Best of luck!

[exvalvesetdabbler]

It's a while ago , but what I  remember doing was to lay the collector box down on some old blankets and have a second pair of hands to hold it down.  Insert the gasket into the collector box.  Make sure there are no burrs on the end of the downpipe and insert it into the collector box while rotating it backwards and forwards and pushing at the same time, you wont get much swing the further it goes in.  Put a straight edge along all 4 pipe flanges to ensure that they are all in line. A smear of high temp silicone grease or copper anti seize grease may help.  Once on the bike tighten, up the clamps on the collector box last and wrap tape around things if there's risk of a scuff somewhere.

It was getting the silencer bracket holes to line up on the frame that caused me some frustration.


Regards
Dave