Fabricating Exhaust Parts

[EricTheCarGuy]

Aside from needing more practice with my welder, I think this turned out well. Before you get mad about the gaskets being reused, I replace them in another video. So what are your experiences with fabricating exhaust?

Topic

[Mario Sarli]

Hello Eric,
Please share with us:
– Which wire did you use in MIG welding your exhaust parts?
– Which shielding gas was used?

I’m working on my leaky exhaust (subaru outback) and taking a different approach — I’ll replace everything from the catalitic converter to the end, using Stainless Steel. Any tips? Also, would you recommend a site to shop for Stainless Steel exhaust parts online?
Thanks!

[Nick]

This is one thing that I do at my job all the time is exhaust fabrication and repair. I weld flex pipes into VW’s and Audi”s all the the time. I do a bit on Honda and Toyota. The flex pipes on the V6 Toyotas such because those nuts never want to come off. I replace flanges all the time, weld in new hangers that rusted out. I even do the occasional pipe bending. I have a bender and expander at work which makes fitting pipes super easy.

Do you have a rusted out flange on your Subaru? Stainless steel is very pricey. I know the flange right after the converter and going into the muffler on those rust out all the time.

[Mario Sarli]

Thanks.
What welding do you use (If MIG, put the details please)? Also, is there a site you recommend for online purchases?

[Nick]

I use MIG. At work we have a MillerMatic 185. Its a 230V welder. Use .035 wire and a mix of 75% argon 25% CO2 for shielding gas.

[dan]

you know eric, not too sound sappy and corney, but your work has always been a inspiration too me, and when it comes too this hand fabricated kind of thing, i applaud you, well done on that exhaust! you have done much better than i could have.

PS what do you plan to do with this car? i like it, kind of a good old classic in a way some sentimental value i suppose.

[EricTheCarGuy]

[quote=”sarli” post=102413]Hello Eric,
Please share with us:
– Which wire did you use in MIG welding your exhaust parts?
– Which shielding gas was used?

I’m working on my leaky exhaust (subaru outback) and taking a different approach — I’ll replace everything from the catalitic converter to the end, using Stainless Steel. Any tips? Also, would you recommend a site to shop for Stainless Steel exhaust parts online?
Thanks![/quote]

I didn’t change the settings much after making this video.

[EricTheCarGuy]

[quote=”13aceofspades13″ post=102581]you know eric, not too sound sappy and corney, but your work has always been a inspiration too me, and when it comes too this hand fabricated kind of thing, i applaud you, well done on that exhaust! you have done much better than i could have.

PS what do you plan to do with this car? i like it, kind of a good old classic in a way some sentimental value i suppose.[/quote]

Thanks very much for your comments. As for the car, I’m kinda falling in love with it. Not sure if it’s all the work I’ve put into it, or what, but I’m not wanting to drive anything else right now. It’s quite the reliable POS.

[Steve Webb]

Evening guys, hope you’re all well.

Caught this video a while ago before I started to learn welding. Well, now I’ve got about 3 hours’ MIG welding practise under my belt and I can tell you I need about another 100,000 hours! lol.

I’m working on the thickness of steel that my welder can REALISTICALLY weld and that’s up to
3 – 3.5mm. I can lay a bead absolutely no problem. I’ve also done some lap welds and they turned out ok. But I am having so much trouble with butt welds.

Even with leaving a small gap and on very thin 1.5mm steel I still cant get the two metals joined so that the weld comes all the way through. Example, my butt welds look like the ones on the left in this pic…
[URL=http://s1226.photobucket.com/user/webbybear1/media/penetration_zps0711e3ee.jpg.html][IMG]http://i1226.photobucket.com/albums/ee402/webbybear1/penetration_zps0711e3ee.jpg[/IMG][/URL]

Anyways, that’s my problem and I’m hoping doing some bevels will help.

However, regarding the video my question is this:

Eric, you welded the flanges on and ran the bead inside the flange on the catalytic converter. Obviously its impossible to tell what penetration you got cos they looked very thick. So if you or others were doing this and the penetration wasn’t great would that not be a real problem with exhausts cos the hangers take all of the ”bounce” out when driving? OR would your welds break within a short time if the penetration was bad?

[Author]

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