Hey guys! New to the forum. I know this thread is a year old, but I just installed the Vance and Hines Dresser Duals on my 2013 CVO Ultra. I was looking for help and came across this thread. I too noticed a leak; air coming out at the crossover pipe/header joint. Same here...re-adjusted the pipe at least 3 times. I called V&H yesterday for guidance. The first guy didn't have an answer and put me on hold. I was on hold for so long, the phone re-dialed and gave me a different person. I explained the issue to a second guy and he said he was familiar with the leak. He added that in talking with their top dyno guys, the leak was normal. Like pbadasay said earlier...whatever that means! LOL
I'm thinking it's definitely a design flaw. Unlike your mufflers and stock Harley crossover that slip "ON" to the header, this pipe slips "INTO" the header. You're bound to have a leak with that type of setup. I've thought about either going to Harley and buying their crossover pipe gasket or just add a little dab of Permatex Muffler and Tailpipe sealent to the bottom of the pipe where it's leaking.
Anyway, I'm glad to see it's just not me having the issue. I installed the headers by myself and thought I screwed up!!
Ride safe...