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I plan to install a downpipe in my MKIV this weekend.

Are new gaskets generally needed? What about the O2 flange?

Are they pretty much std. sizes that any NAPA would have in stock or special order from Toyota?
 

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I installed mine last week and used that high temp copper gasket sealant that comes in a squeeze tube (any good auto parts store will have it). You can use this stuff for the O2 sensor seal as well.

The only things I ordered were new nuts and bolts for everything.

Remember, soak the bolts with Liquid Wrench or equivalent several hours or longer before attempting to remove them.

A good breaker bar helps too.
 

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As far as i know the stock nuts are locking ones that typicaly aren't supposed to be used twice. The first time i swapped my downpipe it was fine....the second time i was snapping studs, and stripping studs. You may wanna use different nutts with washers if you want to remove the downpipe again...
 
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