Manifold to head exhaust leak
 

I've got an exhaust leak off of runner #1 and I'm just wondering what is causing it/how to fix.

I used a new gasket and Permstex Ultra Copper sealant. It was good for a few months. Then after some hard pulls it started leaking. I pulled it off, replaced all the studs and nuts, used a new gasket no sealant this time. It was leaking right away. The manifold is welded els, all mild steel.

Do I need relief cuts? Do I need to get it milled? ( anyone know a price/and place around Chicago? ) Different gaskets? (I'm using stock)

I attached a pic of my mani and marked where it's leaking

Yes, you need relief cuts, and you very likely need to have the manifold surfaced. I dunno if a mill or a belt sander is the right choice -- ask a machinist. I would expect < $100 to get it surfaced.

RTV is not useful on an exhaust manifold.

--Ian