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I actually replaced the muffler already. The old one was a tiny bit warped on each flange. Seems dumb now, but I didn't double check the new muffler flanges flatness, but I'll give it a check. Thanks for the suggestion.

Thank you. The old muffler was leaking before replacing the heads (replaced both sides) and after. The new heads with the new muffler strangely leak in the same place. I'll double check for carbon.

bertsmobile1, thanks for you questions. Answers below. I've tried with three new gaskets. It's leaking basically halfway between the two bolts that go into the head, from between the head and muffler flange (and gasket). I didn't torqued to spec the first time (and probably flattened the gasket...

Any suggestions on how to fix exhaust leaking at the head on a 24HP vtwin? I've replaced heads (separate reason), muffler, and gaskets. Also tried to add some high temp gasket maker. Exhaust gases are leaking out between the head and the muffler flange, no matter what I try. Any other...