Welding up a car exhaust

[Cigaro]

Hi all

The pipe on my car has rusted through and snapped at the join with the backbox. I am wondering if it is worth trying to stick weld it or if it's pointless even trying?

Any tips for welding stuff this thin with an arc welder? I'm pretty shit at welding yet but I've been practicing a lot.

Cheers.

[pepperami]

i`ve tried welding corroded joins on exhausts before , in the main it does`nt work and unless your a good/professional welder, you will end up with even less exhaust as you blow holes in it

well thats what happened to me!!!!

poke a bit of metal in the hole and wiggle it about and see how much more corrosion there is around that hole.
you may be only able to see a small part of the corrosion from the outside, but inside a lot more may be rotten.
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[Ichy]

With a stick welder it would be better to plate the hole, start the arc on the patch piece and run onto the exhaust to reduce the agresssiveness and heat of the arc. You could also consider puddle welding the plate. This assumes that you can find some decent material to weld the plate to .

Another option is to get some pipe with an ID close to the OD of your exhaust. Split the pipe in half, clamp around the split, and weld the two halfs back together.

Generally not worth the trouble welding monkey metal exhausts with a DIY arc welder but if you can get your hands on a carbon arc torch then you can have a go at brazing a patch on there.

[ZRX61]

It's gonna end in tears..

[reggie]

dont even try it with a stick welder you will end up chaseing holes

you could just replace the back box with a bit of pipe what car is it btw ?
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[kingsmith]

by the time you have fucked around trying to weld the back box , you might as well get a new one fitted.
10 mins in an exhust place job done. i never bother with trying to fix exhaust anymore just not worth it.
so cheap now a days, well unless you have some realy expensive system. but most not so.

luck
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[Ariel Badger]

You can do it but do not use Mild Steel rods. Go to a specialist welding supplier and as for some "Gapex" rods, specify the grade for welding rust to nothing other than cruddy carbon and oil.
Good luck.
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[Robby]

Welding thin stuff, unless you're good at welding, isn't going to work.

For an easy gypsy repair, the exhaust repair kits in halfords are ok. You get a metal sleevey thing and lots of exhaust putty, I add lots of jubilee clips as well. I did one of these repairs on my woman's car where the front pipe had split on the flexi joint, a month later and it's still holding. I think the kit cost just under a tenner.

[andybon]

As already said it will probably be less hastle to get a new one.

The one on my car blew through on one of the boxes. When i had a closer look it had gone further down the exhaust. Chances are if its gone in one place, Theres another part ready to blow through somewhere else.
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[temeluchus]

As Ichy said, youd have more luck brazing a patch on than welding.
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[binge]

Polo 1.4?

The middle and rear are sleved together on them exhaust systems. If it's rusted enough to cause a break on the join, You will be lucky to get away with replacing just the middle or rear box.

Off memory, Middle and Rear on a polo is roughly ?90, Fully fitted in our place.

You could probably buy the bits from an autoparts supplier for about ?70, And fit them yourself.




Ben

[Ariel Badger]

[binge]

[dansrockin]

ive got a peugeot 206 gti180 that i had the same problem with last week. the bit of the mid pipe that goes up over the rear suspension was looking like swiss cheese and making a noise like thunder! the back box was also ballsed up with the heat shield skin being half ripped off from having hit something on the road.
the quote from pug was just under ?800!!! for a mid pipe and back box. i went to several exhaust places and they all said they couldnt get the parts for this car. on ebay there are a few places selling stainless steel exhausts for around ?350-400, but a freind from work had a go and managed to cut out the shit from the pipe and make and weld plates over it, and also reskin the back box for the mighty sum of ?15!! it looks like new, is gas tight all over, has replaced all the lost power and saved me a fortune!
it might go again somewhere else but im getting rid of the car in march to be a full time biker so as long as it last til then im not bothered!!! lol
dan

[ZanderJay]

If you are beginner in the welding process, it might be that you can need weld your car into other. It is for the real safe of your car. However, arc welding can be good for that problem, this will be your good choice.
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[Blue_SV650S]

Give it a go ... I always figure 'gotta be worth a try'

Here is my latest arc-magic ...

https://www2.bikechatforums.com/viewtopic.php?t=202880

I have also repaired minimoto expansion chambers (split down the join). Again, not pretty, but it works ... just make sure you have some thin rods.
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[Blue_SV650S]

[kawakid]

[binge]