Can You Rod Weld Mufflers?

You can use both MIG and stick or rod to weld mufflers.

Although the vast majority of shops and independent workers use the MIG (wire-feed) process, welding mufflers with stick or rod is perfectly acceptable. Always wear the proper safety gear when welding.

Choose the Correct Rod

If the muffler housing is made of aluminum, use aluminum rod filler for a secure bond; if the material is steel, use steel filler. Welding aluminum with steel rod will cause the weld areas to rust.

Complete Welds

Always weld completely around the muffler fittings when at all possible to prevent exhaust leaks. Sometimes clearances make this extremely difficult. MIG processes make getting to the top quite a bit easier, but an experienced welder can accomplish the job using a rod.

Be Aware

To prevent catastrophe, check for oil or gasoline before welding. Know the location of the fuel lines are, and protect them from heat and sparks if welding under the vehicle. Also use extreme caution if welding near the fuel tank.

References

• "Welder's Handbook, RevisedHP1513: A Guide to Plasma Cutting, Oxyacetylene, ARC, MIG and TIG Welding"; Richard Finch; 2007