Exhaust welding advise.

[Gurp]

Going to weld up a exhaust for my chopper project. Just looking for a tad of advise. I have HF fluxcore and a Lincoln AC225. I was thinking if i turned down to around 50ish amps and ordered some 1/16ths rods it would be better. Opinions from people that have more exp than me? (Virtually anyone pretty inexperienced as a welder)

 

[TommyK]

You are going to struggle mightily with either of those processes. Mig with shielding gas at a minimum. Tig if you want it to look pretty.

I fabbed a 2.5 inch dual exhaust system for my Mustang using straight pipe and an assortment of mandrel bends using a small 120V Lincoln mig with C25 gas. I wouldn't even think of trying to use flux core or stick but maybe you are a lot better welder than me.

 

[welder4956]

You are going to struggle mightily with either of those processes. Mig with shielding gas at a minimum. Tig if you want it to look pretty.

I fabbed a 2.5 inch dual exhaust system for my Mustang using straight pipe and an assortment of mandrel bends using a small 120V Lincoln mig with C25 gas. I wouldn't even think of trying to use flux core or stick but maybe you are a lot better welder than me.

I agree. Kinda like changing a tire with a pipe wrench. You may eventually get the job done, but wrong tool for the job.

 

[BryceW]

Like stated above, I wouldn't do it with either. Now if I HAD to do it I would use flux core and run short stitch welds to minimize the heat and give yourself a chance of not blowing through. Exhaust tubing is thin and soft so you're working within a somewhat narrow window as far as heat goes. The problem with running stitch welds is you're going to have a very high chance of exhaust leaks where your stops/starts are.

I would use this as an excuse to get a MIG setup and then run .023 wire.

 

[1953mercury]

Unless it's a rat bike, or more accurately a dead, stinking, rat bike, forget the flux-core and stick weld routes. All you will end up doing, is wasting pipe and getting very frustrated. As said above mig with C-25, and .023 wire minimum, or tig. Mike

 

[lilredex]

It can be done with that AC225. Here's an example done on 2" conduit with 3/32" X 7014 rods. A bit lumpy, but leak proof. You could do a bit of grinding to smooth things out and have a bit better looking job. I did it that way mainly to see if you could.

1/16" rods will be a lot more difficult as they burn really hot.

 

[jubilee]

I’ve got a stitch welding attachment for ac stick welding machine. Bought it years ago. Don’t know if they’re still available or not. Eastwood use to have them. Mainly used in the day for body shop panel welding.
I use mine to weld exhaust pipe on car. You can bend rod and weld top of pipe and hard to reach areas. Device simply strokes rod in and out at 60 cycles so rod won’t stick or burn through. Length of stroke is slightly adjustable.

 

[BD1]

Maybe consider inserting a sleeve or ring inside. This will help with alignment and provide more metal to help prevent burn through.
Mig and gas 75/25 would make it easy.

 

[toplessHO]

It can be done with that AC225. Here's an example done on 2" conduit with 3/32" X 7014 rods. A bit lumpy, but leak proof. You could do a bit of grinding to smooth things out and have a bit better looking job. I did it that way mainly to see if you could.

1/16" rods will be a lot more difficult as they burn really hot.

holy mandrel bends,thats a lot of work

 

[toplessHO]

Used to do exhaust work with a gas torch(remember that type welding?) #4 tip
and some mild steel rods

 

[jubilee]

Used to do exhaust work with a gas torch(remember that type welding?) #4 tip
and some mild steel rods

Yeah, when we were kids, we used coat hangers for filler rod. Brings back memories. Pumping stock mufflers full gun grease to get that glass pack sound.

 

[speed bump]

I've done some exhaust repair work with 1/16 6013 on AC. It wasn't terrible but it isn't something I would do by choice. Since I am guessing you don't have the myriad of tools that make fitting pipe together easier ask yourself; do I want to spend an hour recutting a piece because I blew a hole in it chasing the puddle?

 

[dogdog]

I Mig or Tig mine, sometimes combo of both... what a fun PITA project...

here is the thing I learned when I was doing mine...

1) slip joint / expanded joint if you can...
2) mig / probably stick would **** at **** joints.. so if you have to do a lot of bend with **** joints... you'll going to have some ugly welding. THe better your pie cuts the more easier it welds up..
saying that, you having a HF (probably older from description) might ****.. stitch weld like what others have said...

3) Hope you have a good height working under the car... those sparks *****.. and crawling under the car back and forth *****...

Ebay sells some UJ bends that you can use to cut pieces to match the bend you want. if you are doing the whole exhaust, exhaust places have a kit you can buy... for cheaper...

I got my hardware from mandrelbendsolutions , probably comes out cheaper than buying individual pieces...

Even cheaper if I don't mind crush bending and take it to the local exhaust shops.... they got it done on my honda in 45 minutes while I watched... and came out cheaper than I can piece it together...

here is the pic of mine from almost 8 years ago... not shown is the PITA over the axle hump bends, this is also the hardest part of the DIY exhaust fab..... that needs to be tack and fab with the pieces in places, if you moved, or misaligned something... it gets ugly fast..... I used combo of 3 bolt and 2 bolt pattern stainless flanges(from Ebay some guy from NH..) forgot if it was 3/8 or 1/2 thick... If I were to re-do it again, I would have used the V-bands.. probably this summer ... Maybe....

 

[BryceW]

I got my hardware from mandrelbendsolutions , probably comes out cheaper than buying individual pieces...

Even cheaper if I don't mind crush bending and take it to the local exhaust shops.... they got it done on my honda in 45 minutes while I watched... and came out cheaper than I can piece it together...

I've always used the kits from these guys too. Good price for nice clean bends and you've usually got plenty of pipe to cover a mistake or two. I hate crush bends so I wind up doing all my own exhaust work.

 

[Gurp]

Rat bike project..
I figured the smaller stick wouldnt be as hot.
Those options are listed bc thats what I have. I did weld up the exhaust on my D21 with the fluxcore ok.

Man i probably not a better welder than anyone on here.

 

[Backwodsurvivor]

I prefer to keep my exhaust systems short and sweet. Dump it under the cab and be done. Weight reduction or something...

 

[JMLangford]

Used to do exhaust work with a gas torch(remember that type welding?) #4 tip
and some mild steel rods

Yeah, when we were kids, we used coat hangers for filler rod. Brings back memories. Pumping stock mufflers full gun grease to get that glass pack sound.

I worked 2 years in a muffler shop and used only a gas torch and steel rods....also did the coat hanger thing too.

Could lay down some good lookin' beads with a torch

It was exhausting work lol_hitti) but I miss it sometimes....


.

 

[Gurp]

I worked 2 years in a muffler shop and used only a gas torch and steel rods....also did the coat hanger thing too.

Could lay down some good lookin' beads with a torch

It was exhausting work lol_hitti) but I miss it sometimes....

.

I heard a guy at work talking about using a coat hanger in a stick machine before. Idl of there is any truth to that though.