Welding question

[RD350]

Dear all: I am in the process (first time novice) of rolling cones for my 2 stroke exhaust mufflers and then having the seams welded by a fabrication shop.
I am using 20ga galvanized mild steel sheets.
So the question is, is it ok to weld on zinc galvanized sheets or does it require a special process or do you suggest I just used non-galvanized sheets. The reason I want galvanized is cause I am not going to paint them and this will prevent from rusting. Appreciate your help. Thank you kindly.

Regards,

Daryl

 

[MP&C]

The galvanized sheet will present issues for the guy welding, it may require removal of the galvanized coating, and at that point rust becomes a problem again. It's likely quite a cost difference, but stainless sheet would take care of your rust issue. It would need a back purge but would give a much better (and more permanent) job.

 

[astroracer]

Like Robert mentioned, the galvanized coating will have to come off before welding. It will contaminate the weld but also creates "not good to inhale" fumes as it is burning off. You will have to paint the welded area to prevent rust.
Mark

 

[MoonRise]

Options:

1 - Use plain mild steel, roll the cones, weld the seams, then galvanize.

2 - Use stainless steel, roll the cones and weld the seams.

Notice that welding galvanized sheets wasn't listed as a 'good' option.

tech notes: To weld steel, you need to be actually welding the steel. Not rust or oil or paint or zinc coatings (galvanized). So the zinc really has to be removed from the area around the weld seams before welding, which means you are back to bare plain steel on and near the seams.

IMNSHO.

 

[Lonnies Performance]

Paint does not stick well to galvanized metal anyway. Go mild steel.

The oil from a 2 stroke will prevent rust on the inside & you can paint the outside.

Stainless has a different thermal conductivity & will alter your pipe size calculations.

 

[Old Man Roger]

If I remember correctly, welding galvanized steal can produce mustard gas. Really really really bad for the central nervous system. And yes the coating would need to be ground off where the welds were going to be, the welds would rust.

Like mentioned above, SS exhaust looks great and won't rust as long as the proper filler is used.

 

[rlitman]

It produces zinc oxide "smoke" that can lead to metal fume fever.

 

[MoonRise]

If I remember correctly, welding galvanized steal can produce mustard gas. Really really really bad for the central nervous system.

No.

Welding or otherwise heating zinc hot enough to vaporize and oxidize into zinc oxide vapors can cause Metal Fume Fever.

Zinc oxide ointment or lotion is in some skin creams/ointments/lotions and in some sunblocks. No problems there.

Breathing in zinc oxide fumes can cause Metal Fume Fever, which is usually like a really bad and intense but short-term case of the flu (like 24 hours or so). Unlikely to kill you.

Arc welding near old-style chlorinated brake cleaner (or other chlorinated solvents) can form phosgene gas from the intense UV. Which can KILL you.

 

[Old Man Roger]

No.

Welding or otherwise heating zinc hot enough to vaporize and oxidize into zinc oxide vapors can cause Metal Fume Fever.

Zinc oxide ointment or lotion is in some skin creams/ointments/lotions and in some sunblocks. No problems there.

Breathing in zinc oxide fumes can cause Metal Fume Fever, which is usually like a really bad and intense but short-term case of the flu (like 24 hours or so). Unlikely to kill you.

Arc welding near old-style chlorinated brake cleaner (or other chlorinated solvents) can form phosgene gas from the intense UV. Which can KILL you.

I have a terrible memory Either way you don't want to weld it..lol

 

[rlitman]

...Breathing in zinc oxide fumes can cause Metal Fume Fever, which is usually like a really bad and intense but short-term case of the flu (like 24 hours or so). Unlikely to kill you...

True, but it is also known to destroy your senses of taste and/or smell.
The good news about zinc oxide "smoke" is that it's a particulate that's relatively easily for a mask to filter.

 

[turbowoodworker]

I’ve been around 2 stroke bikes all my life. I can’t recall rust on the exp chamber ever being high on the list of 2 stroke problems.

They seize often enough that you can steel wool the exhaust when it is off the head!

 

[tarmy]

True, but it is also known to destroy your senses of taste and/or smell.
The good news about zinc oxide "smoke" is that it's a particulate that's relatively easily for a mask to filter.

I use this...

 

[RD350]

Gentlemen -

I thank you one and all for your expert advise. I also did some quick research on the internet (thank you Google) and confirmed that it is poisonous, and I’ve decided to not weld these sheets as it goes against my personal safety conscience, so welding these sheets ain't gonna happen. I thank you all once again for educating me on this.
So I went ahead and bought another set of mild steel sheets of 20ga. I have also bought a slip roller.
I need to get this rolled into cones with a 1.5 inch inlet dia and 4.5 inch outlet dia .
My biggest challenge will be to get it rolled into the 1.5 inch dia at one end.
After I cross that bridge, I will then need to get the seams welded and then the cones joined together to form the pipe. Could someone please tell me what type of welding is this in the attached pictured? Is this TIG? Thank you kindly and have a great day all.

Kind regards,

350GUY

 

[Old Man Roger]

Unless that was done by a machine, yes it's most likely TIG.

 

[RD350]

Unless that was done by a machine, yes it's most likely TIG.

Thank you Mr. Roger, much appreciated.

 

[mrbracket]

Let's see this RD350!! All this talk about 2smoke pipes is great, but I wanna see the bike it's going on. =)
I'm into Dual Sport Bikes myself, so I've always had an eye for the Yamaha TDR bikes. And of course there's always the Banshee ATV..... I digress...

 

[toolchaser]

Is Aircone still in business?

 

[Old Man Roger]

I may have been wrong about how those pipes were welded. Someone posted some pictures of some pipes in another thread, they were saying they were done with oxy/acetylene.

 

[kazlx]

It's most likely going to be TIG. Back purged stainless is going to be your best avenue. If you want to practice a little and weld it yourself, DC only tig machines can be had semi-inexpensively and there are some AC/DC TIG machines getting good reviews that are (relatively) affordable like the AHP. Just depends on how involved you want to get in your project or if you see yourself wanting to do more welding after this.

 

[gearhead1]

I hold my breath for what little I weld on galvanized steel.

 

[Bopbop]

I have not smelled bacon frying in 30 years. I got the zinc fever really bad and it fried my sinus membrane. Trust me stay away from welding galvanize steel.