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Some exhaust welding help needed

  • Thread starter Thread starter limp
  • Start date Start date May 31, 2024
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limp

wrap a little cheese around it and its a done
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#61
  • Jun 8, 2024
  • #61
Practicin welding on the old single exhaust muffler Going to take a cut off piece of the hanger and see what happens when I try to weld it to this old muffler.... Based on my practice welds to this old muffler, looks like I won't have the burnthrough problems like I had on the car floor.... One reason this project is dragging a bit, I don't want to mess up any of my new exhaust items..
 
Last edited: Jun 8, 2024
Reactions: General karthief

limp

wrap a little cheese around it and its a done
5 Year Member
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#62
  • Jun 8, 2024
  • #62
Here is a pic of a new and a bent exhaust hanger....
I tried to heat it with my propane torch and really not sure if it helped much or any at all... Waiting for it to cool down to check the fit was really time consuming and I thought about renting a car trailer to haul it to a muffler shop....
Ended up clamping it in the vise and just hitting it with my 4lb hammer.... The hangers seem very malleable ( they bend well) and I was pleased with the results I got NOT using an heat.. The bent hanger in the pic was done with NO heat....
Both sides are ready to weld to the back of the mufflers... Hopefully later today I can post a welded picture...

I installed the 99-04 muffler hanger brackets that have two arms each for two hangers on each pipe.... With my tailpipe conundrum, I think I will weld the hanger that goes on the muffler only at this time, then when the car is back on the ground decide if I will install the correct LX tailpipe... The hanger, that attaches to the second arm on the 99-04 bracket, welds to the tail pipe... I can come back and do this later to which tailpipe I decide to use...
 
Last edited: Jun 8, 2024
Reactions: General karthief

2000xp8

SN Certified Technician
Aug 8, 2003
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#63
  • Jun 8, 2024
  • #63
I wouldn't weld anything until you sort out what you are doing with the tail pipes.
Clearance with 2.5 pipes can be a pain in multiple places. If you land up mixing and matching brands and catbacks it will surely involve tweaking (which is why i like bolt together catbacks, infinitely adjustable).
Sometimes they hit the axles tubes, other times they hit the upper control arms and then you have the pipes hitting the corner of the gas tank.
With a GT exhaust that really can't be seen you can align it however you like to make it not hit, you mess up lx tail pipes and it will be obvious because most tips are slash cut.
There is a lot of twisting and turning of the parts to get it all straight.
 
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limp

wrap a little cheese around it and its a done
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#64
  • Jun 8, 2024
  • #64
2000xp8 said:
I wouldn't weld anything until you sort out what you are doing with the tail pipes.
Clearance with 2.5 pipes can be a pain in multiple places. If you land up mixing and matching brands and catbacks it will surely involve tweaking (which is why i like bolt together catbacks, infinitely adjustable).
Sometimes they hit the axles tubes, other times they hit the upper control arms and then you have the pipes hitting the corner of the gas tank.
With a GT exhaust that really can't be seen you can align it however you like to make it not hit, you mess up lx tail pipes and it will be obvious because most tips are slash cut.
There is a lot of twisting and turning of the parts to get it all straight.
Click to expand...
You don't consider this a bolt together exhaust? I have clamps on the front and back of both mufflers?
 

2000xp8

SN Certified Technician
Aug 8, 2003
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#65
  • Jun 8, 2024
  • #65
Sure, but it's not always that easy.
Tail pipes vary by manufacturer.
Some are one piece over the axle, some are two.
Some reach all mufflers, some don't.
And some plain old run a different route. That's why there are only certain kits that fit with panhard bars and torque arms.

Realistically, you could slap it together in minutes, or pull your hair out for hours.
If you weld that hanger on and it has to be moved, there is a good chance you may have to grind it off.

The dynromax ultraflo welded (muffler name) lx catback i have required the hangers to be welded to the mufflers.
I got it where i wanted, then welded it. Though I do have a saleen kit, so that does make alignment tougher.
 
Last edited: Jun 8, 2024
Reactions: limp
R

Rcdgl

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Feb 19, 2018
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#66
  • Jun 27, 2024
  • #66
Have had very good luck with Airgas, probably because I started with them back in 12 or so. I think I bought the first bottle, and have been swapping them out since then, until I went to my neighbor, who gets his from Airgas, swaps them for less. Currently about $90 or $135 for a swap.
 

limp

wrap a little cheese around it and its a done
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#67
  • Jun 27, 2024
  • #67
A long time ago ( way before Al Gore built the internet) there were car magazines....
Hooker headers had a one page ad with a guy sitting on a roller seat under a car on a car lift... He looked dejected, dirty, tired and he was holding some exhaust and header pipe in his hands.....
A great ad, it stated something like " Bill Smith failed today... Crossmember, engine compartment, steering shaft, sometimes our headers don't get built in a day"........ Well that is me.... Mine would be, " Old fat guy, lying under a car, NO past welding experience except watching others... Welding mask slipping sideways and off his head, leg cramps, shoulder aches, can't get an arc going...... Scared he was going to burn through his new mufflers.....He gave up...

I don't know, but I think I could not get a good ground, even though I tried it in multiple spots I cleaned..... Just don't know, not enough experience...

My exhaust is being help up by bailing wire ( electric fence wire too be absolutely correct) I was going to rent a UHaul car trailer and tow it to the muffler shop, but I think I will try to drive it there after it runs...
Heck, when I was a younger lad, we bailing wired alot of exhaust systems and called it good...........
 

General karthief

wonder how much it would cost to ship you a pair
5 Year Member
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#68
  • Jun 27, 2024
  • #68
Seems as though I hinted around to that back when this began, I think, that's what I did, I would have drove it over open headers but since I own a tow truck had it apart at least twice and it just fits right back together easy peasy.
 

Rdub6

So while I wait to figure out my rear end issues
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#69
  • Jun 28, 2024
  • #69
rednotch said:
Tree hugger .... I went to parts store to buy wax and grease remover for a paint project... Its gone, NY banned it seems NJ retail stores just dropped it. Heard there banning oil based paints to wtf, can't even buy rustolem cans soon.. I had to get it from body shop my brother works at and holly chit that price doubled.
Click to expand...
Just catching up on this thread, but yep….. I’m in NY and I heard the same thing about oil base paints. Unbelievable! .
 

Rdub6

So while I wait to figure out my rear end issues
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#70
  • Jun 28, 2024
  • #70
limp said:
I am old enough to remember when those were new...
I wasn't a fan of those exhausts but I hadn't forgiven Pontiac ( and the Chevy Z28 ) for ruining the front end on these cars in 74.....
the 70-73 Trans Ams and Z28s were one of my favorite vehicles...... Red car is a 74

Click to expand...
That was the government bumper standards getting in the way !
 

Rdub6

So while I wait to figure out my rear end issues
5 Year Member
Dec 29, 2017
3,953
2,932
153
Long Island, NY
Jun 28, 2024
#71
  • Jun 28, 2024
  • #71
limp said:
Here is a pic of a new and a bent exhaust hanger....
I tried to heat it with my propane torch and really not sure if it helped much or any at all... Waiting for it to cool down to check the fit was really time consuming and I thought about renting a car trailer to haul it to a muffler shop....
Ended up clamping it in the vise and just hitting it with my 4lb hammer.... The hangers seem very malleable ( they bend well) and I was pleased with the results I got NOT using an heat.. The bent hanger in the pic was done with NO heat....
Both sides are ready to weld to the back of the mufflers... Hopefully later today I can post a welded picture...

I installed the 99-04 muffler hanger brackets that have two arms each for two hangers on each pipe.... With my tailpipe conundrum, I think I will weld the hanger that goes on the muffler only at this time, then when the car is back on the ground decide if I will install the correct LX tailpipe... The hanger, that attaches to the second arm on the 99-04 bracket, welds to the tail pipe... I can come back and do this later to which tailpipe I decide to use...
Click to expand...
Keep more heat against that hanger, as it’s way thicker than the muffler, and you’ll be ok. Let the puddle flow from that piece to the muffler steel.
 

limp

wrap a little cheese around it and its a done
5 Year Member
Oct 4, 2020
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Jun 28, 2024
#72
  • Jun 28, 2024
  • #72
Rdub6 said:
That was the government bumper standards getting in the way !
Click to expand...
Yes, you are correct.. I remember the 5 mph bumpers well.....
 

limp

wrap a little cheese around it and its a done
5 Year Member
Oct 4, 2020
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Jun 28, 2024
#73
  • Jun 28, 2024
  • #73
Rdub6 said:
Keep more heat against that hanger, as it’s way thicker than the muffler, and you’ll be ok. Let the puddle flow from that piece to the muffler steel.
Click to expand...
The mig wire kept burning back to the tip...
 

Rdub6

So while I wait to figure out my rear end issues
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#74
  • Jun 28, 2024
  • #74
limp said:
The mig wire kept burning back to the tip...
Click to expand...
Turn up the wire speed.
It’s always a battle. Before I did anything on the car, I’d find similar thickness scrap metals and practice on that first.
I burned through a whole bottle practicing on thin floor pan metal, but in the end it was worth it!
 

limp

wrap a little cheese around it and its a done
5 Year Member
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Jun 29, 2024
#75
  • Jun 29, 2024
  • #75
Rdub6 said:
Turn up the wire speed.
It’s always a battle. Before I did anything on the car, I’d find similar thickness scrap metals and practice on that first.
I burned through a whole bottle practicing on thin floor pan metal, but in the end it was worth it!
Click to expand...
Been practicing on my old muffler and thought I was ready..
I don't think it was wire speed, it acted like it arced towards the welding tip, not the metal I wanted to weld.. I mean ZAP and the wire was gone.. Old fat guy had to squirm back out from under the car to fix the tip each time. STill think I was having grounding issues...

Using FLUX core, Gas was way to ridiculous in price ( first bottle purchase)
 

General karthief

wonder how much it would cost to ship you a pair
5 Year Member
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#76
  • Jun 29, 2024
  • #76
Do what Rdub said, wire speed just a tad slow.
JMO
 
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