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I'm running a 2.5" header and a 3" test pipe but I did have an exhaust leak because I was using the 3" test pipe gasket on the header to test pipe side. I bought an OEM 2.5" exhaust gasket and it works fine. The leak on my exhaust was primarily because the header had oval holes on the flange where the bolts to the cat mount through. Using the 3" gasket caused the flange to have an area that was exposed and not sealed, on the inner part of the flange holes. Although it was barely visible, it was very noticeable with the engine running. Replacing the gasket with a new OEM. Gasket worked for me, maybe it can help you too.
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