I am still in the 'fix every single thing wrong with the car' mode and my to-do list is expanding!

I've blown quite a few header gaskets before and I thought the last set did hold pretty well.

Upon taking them off: they fell in pieces and there is soot on the head side around every single port; it extends far enough to show that every port leaked to some extent.

I've always made sure bolts were super tight...

I've enlarged ports on the heads and hooker headers so the gaskets always had to be matched and all gasket sets were fel-pros. The gaskets basically disintegrated to the touch next to every port.

What options do I have to make sure I get a tight seal? I don't think it's a warped flange because all ports are leaking.

 

Did you check the header flange for flatness, using a straight-edge? What type have you used for past replacements? What bolts are you using?

 

I haven't checked the flanges yet; As it happens on both sides and all ports, I tend to think it might be something else. I will check it anyways.

As far as the bolts, I really don't recall where I got them from; I bought those when I got the headers, which was something like 6-7 years ago. I know at that time I didn't go the cheap route, but I can't remember the origin.

Each time I changed the gaskets, I had to go through a few cycles of re-tightening as I guess the gaskets shrink; I wonder if the damage happens during that time where it's loose.

I've always had the fel-pros, never tried anything else as they always seemed recommended by everyone.

 

It's very possible you warped the flanges, especially if you've been driving it like that for a while. I use Fel-Pro myself, and have no problems.