Hey guys. I ordered a 2.5" cat-back from CTI, and a 2.5" in/out dynomax superturbo muffler and 2.5" in/out magnaflow high flow cat from summit racing. I'm still deciding on a header - its a toss up between cheap ebay (tsudo) or the LSJ pacesetter header.
Anyways, my questions is what kind of welder is adequate for installing the exhaust? I want to try to do everything myself and try to get as many pointers here as possible. What type and are there any special ratings for welding exhaust pipe? I plan to practice on something insignificant before I actually start in on the exhaust
ive used a 110 mig with gas not the flux core wire on exhaust ,worked well , Ive been welding for quite a few yrs (nothing structural but worked as a mechanic for a construction company) when first learning I found exhaust is harder to weld than heavy steel because its realy easy to burn a hole in if ur settings arnt right and then u have to try filling in holes and it looks like crap ,trust me i know from experience lol just remember 1 major rule, your first pass is the most important, if u have to run another pass its mainly cosmetic., if u plan on practicing ,practice on identical material( scrap exhaust pipe) because your settings depend on the thickness of the steel ur using, ur using new pipe so cleanliness shouldnt be a problem(migs dont like rust) when i was shown how to weld, i started off with a 1/4 inch plate about 8in square and ran passes paralel to each other across the plate, then turned the plate 90 degrees and went the other way for what seemed like forever lol, post some pics of your practice welds, Im sure there will be some guys that give u tips on wire speed and heat and so on then once u get the welder set right and u see how it welds and looks when done correctly , u just have to try for that feel and "look" when u weld other materials of differing thicknesses. give it a try, I know lots of guys that have taught themselves to hobby weld just take ur time, hope this helps, its early here and just started my coffee lol good luck.
Thank you! this does help. I'll definately get pics up when get started practicing.
By gas do you mean acetylene? So a 110 MIG welder should be adequate. Now I have to keep an eye on the harbor freight catalog.
argon mix...
Veritas Aequitas
If you can't afford the gas, flux core will also work. I've welded up my exhaust and intake/intercooler systems with flux core. It will be more forgiving if you use gas however, the spatter with flux core can be unreal. A slow speed for your wire feed will tend the best results typically. On my 110 mig/flux welder it has 10settings for speed and I use speed 1.5-2 for most things(1 being the slowest).
Welding is a ton of fun and I think you'll really enjoy doing it. And seriously, take lots and lots of practice, welding pipes is one of the most difficult things to do.
86svo wrote:If you can't afford the gas, flux core will also work. I've welded up my exhaust and intake/intercooler systems with flux core. It will be more forgiving if you use gas however, the spatter with flux core can be unreal. A slow speed for your wire feed will tend the best results typically. On my 110 mig/flux welder it has 10settings for speed and I use speed 1.5-2 for most things(1 being the slowest).
Welding is a ton of fun and I think you'll really enjoy doing it. And seriously, take lots and lots of practice, welding pipes is one of the most difficult things to do.
I wasn't too worried about the price, but I didn't want a bulky tank of gas sitting around for months. Are there small tanks available for purchase? I plan to weld up the exhaust and maybe fab up a cold air intake, and then the welder will sit probably for a long while. Its good to know the alternative will work
yes you can get smaller tanks, but i used flux core on my exhaust as well and havent fun into any problems, just doesnt look the best with the spatter
Veritas Aequitas
So flux core can be used on mild steel and aluminum?
Between welding the exhaust and making a homeade cold air intake from a 50$ ebay intercooler kit, the welder will have already paid for itself
Forgive my amateurs questions, but what makes a bad weld "bad"? Is it solely looks/aesthetics, or can you structurally screw something up?
i know it can on mild steel, but im not sure about aluminum. when i had my stuff welded the guy used a TIG welder.
Veritas Aequitas
Well there's a few things that could make your weld bad, like, lack of preparation, having the temperature set wrong, wrong technique (the way you hold the gun).. and if you're welding something that's dirty or painted. Also you need good penetration... and yes this can structrually weaken the weld
Am I the only person who used a stick welder? lol
2004 Cavalier
13.2@105........
Mods...
BFG Drag Radials
Saab Turbo kit
2.5 exhaust, w/cutout
Spec Stage 2+ Clutch
ECOTEC wrote:Am I the only person who used a stick welder? lol
Nope, 1/8" 6011 rod should weld exhaust fine.
To weld aluminum or stainless with a mig I've always used a spool gun.
ECOTEC wrote:Am I the only person who used a stick welder? lol
^^YES! lol. Stick welders are soooooo old-fashioned, lol. But, it is actually easier to do MIG welding than arc, you don't have to "create" the spark.
As to the OP, I wouldn't use a mig on aluminum, you should have that TIG'd. Laying a good weld will be both, aesthetically and structurally sound. When you lay a weld that is clumpy and uneven, you don't truly know if you have a potential air leak until you try out the pipe. You could grind down the "lumps" if you are unsure, but anytime you have to go back over a weld, it weakens the integrity of the joint. However, seeing as how this pipe is not going to bare any load, you should be fine grinding and re-welding, just won't look so nice!
If you have any other q's just let us know, and like I said before, practice and practice and practice. Go to autozone and buy some of the cheap 2' sections of exhaust pipe for $5, cut it up into six pieces and practice away. Keep it slow and steady, it's easier to run the bead downhill than it is uphill(think of the bead as the leading section of a lava flow). I would advise also on picking up a book at Barnes and Noble's about welding, lots of great tips in a few of those books.
Jason
