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This is a discussion on Pie cut exhaust within the Technical forums, part of the Caferacer.net Forums category; Welding comes in handy when you need to make up a quick tools also. Attachment 55761...

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  1. #101
    Senior Member nic579's Avatar
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    Welding comes in handy when you need to make up a quick tools also.

    Attachment 55761
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  2. #102
    jcw
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    Nova, your coped tubing joint welds are NOT BAD! Maybe hold a tighter arc.


    My suggestion for the coped tubing joints.

    Think of it as a couple distinct welds.

    The right angle section is a fillet joint.

    The flat section is a lap joint.

    Then there are the transition zones.

    There are subtle differences in how fast you move and where you direct the heat (torch angle) and how much filler you add in each section. Practice your lap and fillet joints.

    The smaller you want the bead, the tighter an arc you need to hold.

    I spent 2 months welding coped joints.



    This was too cold.



    This undercut a little too much.
    Last edited by jcw; 03-10-2017 at 06:46 PM.

  3. #103
    jcw
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    This guy is a king of tube welding. Nice guy too that learned to weld on his own by just practice, practice and more practice.

    https://www.flickr.com/photos/zancon...th/8560833492/

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  5. #104
    jcw
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    Quote Originally Posted by nic579 View Post
    Welding comes in handy when you need to make up a quick tools also.

    Attachment 55761
    Helpful around the house too. Tacked up several of the wife's cooking paraphernalia. Did a broken foot off a vegatable steamer this morning.


    I've welded up fixtures for cam timing measurements, TDC tools, clutch holders, various wrench extensions, tire iron tools.

  6. #105
    Senior Member 540nova's Avatar
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    Thanks for the tips, JCW. I never TIG'd before, just got this machine last week. The 1" square tubing I posted earlier was day 2 of my TIG experience. Today's tubing was day 3. It can only get better, I hope!


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  7. #106
    jcw
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    You've got a knack for it then.

  8. #107
    Senior Member 540nova's Avatar
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    Quote Originally Posted by jcw View Post
    You've got a knack for it then.
    Thanks! I've had a MIG for a while. TIG is definitely more challenging at first. Sorta like when you first learn to drive, and it's a stick shift; lots going on, and to think about!


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  9. #108
    jcw
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    Two down. One to go.
    And the midpipe.

    No problems. It's been easy peasy.

    You know you are nuts when after a couple beers you think, you'd rather be out in the garage welding...
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  10. #109
    Senior Member 540nova's Avatar
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    I think that exhaust is going to be awesome you're done.


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  11. #110
    jcw
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    So finishing up the welding part of the exhaust build and wanted to write down tips pertaining to this. Welding for me is a bunch of small eureka! moments and the more you do the better you get.


    Obviously, good fit up is key here. It allows you to weld with as little filler as possible which is good for aesthetics and but also keeps distortion minimized.

    A needle-sharp tungsten tip focuses the arc and allows for a quicker forming and more stable puddle. Stop and resharpen.

    Clean parts obviously goes without saying. Brush with clean wire brush and wipe with acetone. (BTW, NEVER use brake cleaner spray to clean parts before argon welding. Something about PHOSGENE gas and instant death.)

    Keeping a correct torch angle is as important as anything else for a consistent weld. As you move across the tube, if you are so focused on locking your wrist in one position, the angle of the torch and tip drastically changes until you are blowing hot gases almost tangential to the tube.

    In order to keep that consistent torch angle your wrist has to twist along the outside of the tube. Best way I've found to do that is to prop your pinky finger on the tube and let it run along the surface. This was a minor breakthrough for me and my beads immediately improved in appearance and consistency.

    To keep distortion under control, weld in <5sec segments and keep moving. Weld segment opposite to each other. Then wait for the part to cool enough that you can touch the part with your upper lip. LOL.


    Almost done with the header pipes. Midpipe remains and then I need to figure how best to fit the header tubes to the collector. Weld on or slip on. And maybe some massaging of the first header pipe that warped slightly.
    Last edited by jcw; 03-12-2017 at 05:27 PM.
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