How to Weld a Stainless Exhaust System
Welding a stainless steel exhaust system is not recommended for the novice welder, but it is a task that can be completed in the driveway in an afternoon. If you are using a stick welder, use stainless rods so that the welds will not rust when they are exposed to the elements. If you are using a MIG welder, switch to stainless wire.
Things You'll Need
- Welder with stainless rod or wire
- Reciprocating saw or angle-grinder
- Tape measure
Instructions
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Measure the system carefully first. Use a tape measure to figure out how long each section is going to be, and write down the numbers. Also, draw out a rough sketch of how it will look; include all the correct angles so that it fits in well after it is cut. Plan each bend and curve beforehand so that when you do finally cut, you can rest assured that everything is being done correctly. If you are also welding a muffler or catalytic converter in, allow space for them in the stainless tubing when you cut it.
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Cut the stainless exhaust tubing to fit. Cut slow and straight so that the pieces fit together nicely. Remember that when cutting angles, the idea is to cut one single angle so that the two pieces can be turned and fit together to make the bend. Doing it this way will save on material and work, because you won't need "filler" metal in the bends themselves.
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Weld the exhaust system. Weld in spots first, skipping a few inches around the tubing with every strike so that the stainless steel doesn't become warped from the heat of constant welding. Weld for about 3 seconds in one spot, stop and then move on to the next one. Once the joint is fully tacked together, allow it to cool and then go back and fill in the other areas with a straight shot. Weld around the entire circumference of the stainless tubing and leave no spot untouched so that you do not end up with an exhaust leak.
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Tips & Warnings
Always wear safety gear when cutting or welding.
Measuring is the most crucial phase of the entire operation.
References
- Photo Credit welding project image by leemarusa from Fotolia.com
