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Old 07-28-2006, 03:41 PM   #1 (permalink)
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welding exhaust?

what are you guys using to weld exhaust systems together. i have a stock header with a downey cat back system, with the 2in. pipes and the stock ehader is a little over an inch in diameter, and i have an adapter to conctect the two sizes together and this conecter has cracked right in half, what would you guys do to fix this, what welding set up do i need. i have a miller 175.
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Old 07-28-2006, 03:48 PM   #2 (permalink)
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plug in your mm175, turn it on and go.


gas shielded mig would be the easiest.
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Old 07-28-2006, 03:55 PM   #3 (permalink)
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i already tried to weld it but i melted the shit out if the pipe, even with the volts very low
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Old 07-28-2006, 03:58 PM   #4 (permalink)
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tack weld it together - let cool

spot weld - let cool

repeat till done.
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Old 07-28-2006, 04:03 PM   #5 (permalink)
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Quote:
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tack weld it together - let cool

spot weld - let cool

repeat till done.
Exactly. Turn your welder down and weld it in small sections if you keep burning through. What size wire are you using? The bigger the wire the easier it is to blow holes in the pipe.
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Old 07-28-2006, 04:59 PM   #6 (permalink)
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Used exhaust pipe is a bitch to weld; the metal is contaminated with nasty crap but it can be done. You have to go real slow and low, just like the lo-rider motto.
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Old 07-28-2006, 05:54 PM   #7 (permalink)
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Are you using flex core?

I never used that crap but it maybe some of your problem if so.

I've welded a shit load of exhaust with the same welder with no problems at all. While you’re welding your pipes move your gun laying the bead more than normal to alleviate burn throughs. And it goes without saying - clean the fawk outta the pipes before welding - migs hate rust.

Now, if your pipe is rusted really thin, then I'd replace it now.
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Old 07-28-2006, 07:23 PM   #8 (permalink)
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BUY SOME .023 WIRE!

It took a lot of convincing to get me to go spend $$$ buying .023/.025 diameter wire and contact tips. (This assumes you are running it with gas as a MIG, and not just flux-cored wire-feed)

One try on sheetmetal or exhaust with a gas-equipped .023 setup, and you'll be wondering why you didn't know about this ages ago.

You can weld it with flux core, but you'll pretty much be unable to run a bead on used factory tubing. It's paper thin. You'll be doing tack-welds all the way around the pipe. New exhaust tubing from the muffler shop or parts store is much thicker, and easier to work with. When welding it to old factory stuff, concentrate your beginning on the thick stuff, then move over to the thin stuff once the puddle has formed, and let go before you burn through.

Don't even try it with .035 diameter wire. It's possible, as long as you're never on the trigger for more than a quarter-second.
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Old 07-28-2006, 07:39 PM   #9 (permalink)
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I have a Lincoln pro-core 100 , and I am using .035 flux core , can I run .023 by just changing tips ??
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Old 07-28-2006, 07:43 PM   #10 (permalink)
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I'm old school and do it with an oxy/acet rig.
I wonder if "they" make electrodes small enough for exhaust work that I can run on my arc? off to go search......
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Old 07-28-2006, 07:48 PM   #11 (permalink)
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I have a Lincoln pro-core 100 , and I am using .035 flux core , can I run .023 by just changing tips ??
You'll need the conversion kit to use gas.
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Old 07-28-2006, 07:59 PM   #12 (permalink)
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You'll need the conversion kit to use gas.
so .023 does not come in fluxcore??
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Old 07-28-2006, 08:06 PM   #13 (permalink)
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Quote:
Originally Posted by abnormaltoy
You'll need the conversion kit to use gas.

I think the liner maybe different as well.

Yea, you'll need the regulator and lease a $$$ tank for co2/orgon (sp) gas and then pay to have it filled and then the tips and then the wire and then the tip spray or gel and then go fawken weld and throw your flex core crap away and don't look back and this sentence is running on and on and on and on....

Sooooo THAT's what it feels like to be a newbie - fawk I forgot to misqelle ever thing.
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Old 07-28-2006, 08:09 PM   #14 (permalink)
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My opinoin of flex core (Dammmm, you should see this bitch on Dish TV anyway, is an endless buzz box stick. Just go bare.
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Old 07-28-2006, 08:19 PM   #15 (permalink)
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and for the engrish impaired, it's FLUX CORE not FLEX CORE
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Old 07-28-2006, 08:25 PM   #16 (permalink)
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Quote:
Originally Posted by RockStomper-Toy
My opinoin of flex core (Dammmm, you should see this bitch on Dish TV anyway, is an endless buzz box stick. Just go bare.
your adult a.d.d. kicking in
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Old 07-28-2006, 08:41 PM   #17 (permalink)
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and for the engrish impaired, it's FLUX CORE not FLEX CORE
OH Wellllll,


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Old 07-28-2006, 08:43 PM   #18 (permalink)
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mmmm beer.

for some reason I can't weld worth a shit with my oxy/acet rig unless I've got at least 3 beers in me.
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Old 07-28-2006, 08:44 PM   #19 (permalink)
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Quote:
Originally Posted by abnormaltoy
You'll need the conversion kit to use gas.
I googled your welder and there is/are kits for it.

http://www.weldingsuppliesfromioc.co...ons/Categories

a little less than 1/2 way down the page.

Last edited by abnormaltoy; 07-28-2006 at 08:49 PM.
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Old 07-28-2006, 08:46 PM   #20 (permalink)
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I think the liner maybe different as well.

I think the different liners are for aluminum...but you will need the regulator and tips.
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Old 07-28-2006, 09:30 PM   #21 (permalink)
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Quote:
Originally Posted by Richard
I have a Lincoln pro-core 100 , and I am using .035 flux core , can I run .023 by just changing tips ??
Just get the Lincoln mig conversion kit. Installed on my Lincoln 155 a few years ago. It comes with the new liner, nozzle, regulator etc. Also comes with instructions to rewire internals on your welder...reverse polarity or something.
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Old 07-28-2006, 09:37 PM   #22 (permalink)
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For gas just get a 20 gallon co2 tank from ebay or something and swap em out at home depot for 9 bucks. I have to swap mine in the morning, or else I would be welding now.
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Old 07-28-2006, 09:53 PM   #23 (permalink)
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Quote:
Originally Posted by AC
Just get the Lincoln mig conversion kit. Installed on my Lincoln 155 a few years ago. It comes with the new liner, nozzle, regulator etc. Also comes with instructions to rewire internals on your welder...reverse polarity or something.
Buying the kit is the easiest way to get all the right parts...good to have a welder store who knows their chit and is cool.

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For gas just get a 20 gallon co2 tank from ebay or something and swap em out at home depot for 9 bucks. I have to swap mine in the morning, or else I would be welding now.
Do it right the first time...buy CO2/argon mix...much better welding than the cheap a$$ straight CO2...and people wonder why their welds look crappy and stuff breaks at the worst time...
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Last edited by Nate C; 07-28-2006 at 09:56 PM.
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Old 07-28-2006, 11:38 PM   #24 (permalink)
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to run the smaller wire you will need the tip to match, and the wheel that draws the wire will have to be flipped around to the shallow goove, or else it will not push the wire out the tip, or it will but just change speed constantly and mess up your weld. for exhaust I use .023 as well. .035 is a pain in the ass sometimes, especially if welding to existing pipe, it burns through to quik, and you get the holes from contamination. you will need the conversion kit for gas and you need to switch the polarity around.
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Old 07-30-2006, 03:38 PM   #25 (permalink)
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sounds to me like you are using WAY to big a wire go with 25 or 30 and that should do it
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