How to weld mufflers

merc123 · Nov 29, 2004

Yeah, I know take it to a shop. I want to know how they do it.

If I remember correctly, when my dynomax's were welded in the guy shoved a pipe down into each end then welded them in.

Can someone give me a detail explanation? Also, are they 2.25 or 2.5" pipes on a stock exhausts?

8yourZ06 · Nov 30, 2004

merc123 said:
Yeah, I know take it to a shop. I want to know how they do it.

If I remember correctly, when my dynomax's were welded in the guy shoved a pipe down into each end then welded them in.

Can someone give me a detail explanation? Also, are they 2.25 or 2.5" pipes on a stock exhausts?

Depending on the mufflers..they probably put your pipes in a flaring machine or vice versa and expanded them to fit over one another. My stock pipes on my 01 are 2.5".

Tylerb59 · Nov 30, 2004

Should be 2.25'' piping all the way back and 2.5'' tips.

billyfe390 · Nov 30, 2004

Its supposed to be 2.25 but its not mandrel bent so its anywhere from 2-2.25 in spots. When I welded mine in I had to expand the pipes going in and coming out of the muffs so I could weld it.

Rocketman · Nov 30, 2004

Tylerb59 said:
Should be 2.25'' piping all the way back and 2.5'' tips.

Stock exhaust to the tips is 2-1/4 inches.

merc123 · Nov 30, 2004

Good deal. It'll be relatively easy then to weld them in place.

Tom in Tacoma · Nov 30, 2004

A good muffler shop will butt the pipe and muffler together (lined-up) and lay a bead all the way around. Slipping a pipe inside before welding just creates another obstruction in the exhaust path.

merc123 · Nov 30, 2004

Yeah, that's what we planned on doing was just lining up and beading. I wasn't sure if it would cause leaks or not.

myponyrocks · Nov 30, 2004

as long as you can run a good solid bead there should be no leaks. Its not too hard and doesnt have to be pretty, but it should be

Evenflow · Nov 30, 2004

Im planning on getting some Flowmaster Delta 40 mufflers welded in soon. Everything is stock.

Think they will add any performance, better than the stock mufflers?

myponyrocks · Nov 30, 2004

not much, the factory pipes are kinda restrictive, but theres a lil power in there, nothing SoTP that I felt... I felt my prochamber though

Tom in Tacoma · Nov 30, 2004

I added a pair of 3-chamber (50-series) flowmasters to the stock pipes. No noticeable improvement other than sound.

I had originally put a pair of 40-series in. They caused way too much drone at 2k RPM for me. I'm happy with the 50-series deltaflow flowmasters.

Evenflow · Nov 30, 2004

How bad is the drone with the 40's?

Do the 50's have that muscle car sound to them?

myponyrocks · Nov 30, 2004

the drone isnt too bad, I can tune it out... just keep in mind this sound is a very opinionated thing... I kinda like drone for short periods of time.

Evenflow · Nov 30, 2004

I dont think ill mind it to much...

How do the 50 series sound? Muscley?

8yourZ06 · Nov 30, 2004

Tom in Tacoma said:
A good muffler shop will butt the pipe and muffler together (lined-up) and lay a bead all the way around. Slipping a pipe inside before welding just creates another obstruction in the exhaust path.

If the pipe is flared correctly there isnt any obstruction of exhaust flow. In doing that..its a easier weld being a "fillet" weld and its a stronger weld.

Tom in Tacoma · Dec 1, 2004

I had a problem with the 40-series drone since it occured right around 70mph - the speed I normally cruise at. It made it really annoying after a while.

I like the sound that the 50-series put out. I know that I can hear my wife coming down our street when I can't hear any other cars going by. But, as was pointed out, sound is a subjective thing - what one person considers too loud, another thinks is too quiet.

8yourZ06 said:
If the pipe is flared correctly there isnt any obstruction of exhaust flow. In doing that..its a easier weld being a "fillet" weld and its a stronger weld.

Good point about the weld being stronger. Hadn't thought about that aspect...

SpitfireMk24 · Dec 1, 2004

back to welding mufflers. . .

you can rent welders right? most cost efficient would be to rent a welder or borrow one and do it yourself. . . right?

Tom in Tacoma · Dec 1, 2004

You could go to the rental shop and pickup the welder, go home, raise the car, wrestle with getting the old exhaust apart, install the new one, weld the mufflers in place, spit out the grit that landed in your mouth, lower the car, return the welder, pay the rental fee....

...or...

...take the mufflers to a local shop and pay them $30-$40 and drive away a short while later with the job done.

Guess you can tell which road I chose.

DisposableHero · Dec 1, 2004

what about the 10 series 1 chamber? hows the drone on that?

How to weld mufflers

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