Gasket: what to do, how to cut or make a gasket?

Gaskets are an indispensable component of many mechanisms and devices, ensuring tightness and preventing leaks. Whether we are dealing with sealing in an engine, a carburetor, or a thermostat housing, the proper gasket is critical for the correct operation of the whole system. But what can you do when the original gasket gets damaged and buying a new one is impossible or unprofitable? In such a situation, there arises a need to custom‑make or cut out a gasket yourself. In this article we will look at different types of gaskets and materials from which they can be made, and also discuss methods of cutting gaskets by hand.

If you need professional help in fabricating or cutting technical gaskets, contact us — we offer a service of precision-cut gaskets to custom dimensions. Feel free to reach us at +48 22 292 40 24 or +48 505 16 03 03, or by email (Power|PowerRubber.com| |Power|PowerRubber.com), or via our contact form.

Types of Gaskets

There are many types of gaskets, differing in material, construction, and application. Choosing the right gasket depends on working conditions such as pressure, temperature, and the type of medium being sealed. The most commonly encountered are rubber, paper, and silicone gaskets, but there are also gaskets made of other materials such as felt, cork, or fiber. Each of these materials has its specific properties that make it suitable for certain applications.

Rubber Gaskets

Rubber gaskets are technical components with broad use in industry, automotive, hydraulics, and construction. They are characterized by high flexibility, resistance to deformation, and durability under demanding operating conditions. The proper choice of rubber compound determines chemical, temperature, and mechanical resistance of the finished gasket. Depending on the application, various rubber compounds and technical elastomers are used; their properties are summarized in the table below:

Rubber gaskets and technical gaskets made from the above materials are used in both static and dynamic connections, also in systems operating under pressure. In bearings, shafts and hydraulic systems, rubber rings, O‑rings and oil‑resistant gaskets are used to ensure sealing, durability and resistance to operational factors.

Paper Gaskets

Paper gaskets are a popular solution used where a thin, precise seal is required without heavy mechanical loads. They are made from gasket paper, usually about 1 mm thick, which adapts well to the surfaces being joined. They are characterized by low cost, ease of processing, and fast installation, which is why they are often used in workshops and component production. Before installation, the paper may be coated with a thin layer of grease or silicone to increase the seal and aid later disassembly. Paper gaskets are ideal for applications where high pressure or temperature is absent — for example in thermostat housings, carburetors, engine covers and gear cases. They are an economical, lightweight, and effective solution in many technical applications.

Silicone Gaskets

Silicone gaskets are precise technical components with exceptional resistance to temperature, UV radiation, ozone, and the action of chemical agents. Made from high-quality technical silicone (VMQ), they retain flexibility across a wide temperature range — from approximately –60 °C to +230 °C — which allows their use in conditions where other materials would deform or lose sealing properties. Thanks to excellent adhesion to various surfaces, silicone gaskets provide durable, tight and aging-resistant connections.

They are used in the automotive, chemical, food, medical, and electronic industries where high purity and reliability of the material are required. Silicone gaskets are well suited for engines, heating devices, sanitary installations, as well as laboratory equipment and industrial apparatus. Their insulating properties and resistance to extreme conditions make them one of the most durable and versatile solutions in the field of technical sealing.

What material to make a gasket from? Choosing the right material

Rubber: properties and applications

Rubber is a popular material for cutting gaskets due to its flexibility and ability to seal joints. Rubber gaskets, including rings, are resistant to oils and greases, which allows them to be used in engines. They provide good and reliable sealing even under pressure. From various types of rubber compounds you can fabricate a gasket that adheres well to surfaces and resists leaking.

How to choose the right material for cutting a gasket for a specific application?

The selection of material for making a technical gasket depends directly on working conditions, the type of medium, temperature, and pressure. In automotive applications such as engines, oil pumps or gearboxes, rubber compounds like NBR or FKM (Viton®) perform best, being resistant to oils, fuels, and greases. In places exposed to contact with water or steam, such as cooling systems or thermostat housings, EPDM or silicone VMQ is used, ensuring high temperature and aging resistance. For light connections where there is no high pressure, e.g. in carburetors or technical covers, paper gaskets about 1 mm thick suffice and are easy to cut manually. In every case, the key is that the material provides sealing, chemical resistance and durability in the working environment.

How to make a gasket yourself? Tools needed for cutting gaskets

To make a gasket yourself, suitable tools are needed. These include a cutting knife, scissors, a hammer, a center punch, a hole punch for making bolt holes, and a sheet of material (paper, rubber, silicone). A template or an old gasket as a pattern is also useful. It is important that the knife is sharp to cut the gasket precisely. If you want to fabricate a gasket, you must have a tool to cut it.

Step‑by‑step gasket cutting process

The gasket cutting process begins with preparing a template. You can use an old gasket or draw the pattern on cardboard. Then place the template on the material sheet and trace around it. With a sharp knife, cut the gasket along the outline. Use a punch to make screw holes. The finished gasket can be lightly coated with a thin layer of grease before installation. Cutting a gasket by hand requires precision.

Examples of gaskets for DIY fabrication

Examples of gaskets you can make yourself include gaskets for carburetors, thermostat housings, exhaust manifolds, water pumps or cylinders. For carburetors and thermostat housings, paper material is sufficient because pressure is not high in those locations. For an engine it is best to use rubber or silicone. Cutting a gasket for a cylinder requires greater precision.

Selection and purchase of gaskets

Where to buy a gasket?

A gasket can be purchased in many places, but it is essential to choose trusted suppliers offering products with proper technical parameters. In the POWER Rubber store you can find technical gaskets, rubber O‑rings, and flat and flange gaskets made from high-quality materials such as NBR rubber, EPDM, FKM (Viton), silicone, PTFE, or gasket sheets.

For customers who need nonstandard elements, POWER Rubber offers a precision gasket cutting service on request — both from sheets and gasket plates. Thanks to modern CNC cutting technology and experience in manufacturing technical seals, every gasket can be made exactly according to the customer’s dimensions and specifications.

What features should a good gasket have?

A good technical gasket must provide complete tightness and resistance to the operating conditions in which it will be used. It should exhibit:

• Resistance to high temperature and pressure,

• Resistance to oils, fuels, water, steam or chemicals (depending on the application),

• Flexibility and elasticity, which allow it to conform to surfaces,

• Dimensional stability even in long-term use.

Gaskets for engines should be made from materials resistant to engine oils and high temperatures — for example NBR, FKM or high-temperature silicone. Meanwhile, gaskets for fuel systems and carburetors require resistance to gasoline and petroleum substances, so FKM (Viton) or specialized chemical-resistant rubber mixtures are suitable.

What to pay attention to when buying a gasket?

When choosing a gasket, always take into account:

• The type of medium (e.g. oil, water, steam, fuel, air),

• The operating temperature range,

• The pressure level,

• The material of the mating surface,

• The exact dimensions of the sealing area.

If you are unsure which type of gasket to choose, it’s worth consulting the specialists at POWER Rubber, who will advise on the appropriate solution and material.

For customers seeking nonstandard solutions, there is the possibility of fabricating a gasket based on a template, technical drawing or dimensions. This solution is ideal when the original part is no longer available or requires modification.

POWER Rubber specializes in the sale and production of technical gaskets, O‑rings and rubber components for industrial, automotive and hydraulic applications.

Contact us to get an offer tailored to your needs: by phone +48 22 292 40 24 or +48 505 16 03 03, or by email (Power|PowerRubber.com| |Power|PowerRubber.com) or via our contact form.