Exhaust Repair

[valleydweller1]

Hi,

I need to put a new muffler on my truck. The old one is badly rusted; the exhaust tubing up to the muffler appears to be in pretty good shape. I have a stick welder and an oxy-acetylene set; which would be better to use? Any tips on how to do it?

Thanks,

 

[George2615]

I'd use the oxy / acetylene. Exhaust pipe is pretty thin and a stick welder would probably just blow a hole in it. Unless you can dial it way down and use 1/16" rod. The torch set would work better since you can heat the pipe cherry red and flow your rod into it. I've done it before using steel coat hangers or brazing rod instead of welding rod with good success. A mig work probably work well too but didn't see it as an option in your post.
Why can't you buy a muffler that slides over the pipe and clamp it?

 

[BTDT]

Be careful with a torch/welder under the truck (leaky gas lines, rubber hoses, etc.)

 

[Ifixcars]

If the muffler is clamped onto the existing good pipe, remove the clamp by unbolting or cut it off with the torch. You can also use the torch to slice down the muffler snout without damaging the pipe underneath if you're careful. Point the torch kinda towards the muffler and lightly slice a slot down the inlet. Do that on opposite sides and the muffler should come off, maybe with a little persuation with a BFH. Maybe peel the cut pieces away with a chisel if the muffler is stuck. You can also just heat that inlet up red hot and kinda twist the muffler and beat on it a little to remove it. Then just clamp the new one on. If the system is welded one piece, you could use a sawsall cut right in front of the muff. I guess you could torch cut it but I prefer sawing. If the pipe is regular steel you can weld it with smaller rods. 1/8" rods would be a little big. 3/32" 6013 would be ok if the pipe is not too thin. The existing pipe should be in really nice shape to be re-used, or just get rid of it. Pipes usually are not that expensive.

 

[thingy]

Well,can you oxy/act weld? if you can,than there you go,,,clean it good,,get you some gas or tig wire,,or bare coat hanger wire,,small welding tip,[not cutting tip],,and have at it,,,if you can't oxy/act weld,,than I'd get somebody to put it on for me,,you could bubblegum it with stick,,but you would need real small rod,,and alota practice,,,thingy

 

[bx23barry]

Built a few sets of headers with a torch

 

[thingy]

Well,than you the man,,,other than cleaning it and using a smaller welding torch/tip,I couldn't give you no advise,,,other than get a good fire extengisher by your side and maybe do it outside,,,when you get it done,,tell us how it went and how you did it,,,THINGY