Welding exhaust

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I've been trying to weld exhaust for my car. I'm kinda a newb but i can get a decent weld. Problem i'm having is when i'm welding 2 pieces together if there is a little gap, it's burning a hole through where im' trying to weld. I can weld it when it sits pretty much flush but when i hit a gap where the wire might go through it creates a hole.Anyone care to help me prevent this?Forgot to say, im' fluxcore miggin, w/ stainless 3" and some 3" crap metal used on another car's exhaustLast edited by Joe5688; 04-08-2007 at 11:44 AM.
Reply:Fluxcore and exhaust =   most times..A Gas mig is the way to go there..Fluxcore is that much hotter...Only way around it is to "spot weld" the pipe here there and everywhere..If its still on the car then its only 10 times harder to do than off.....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:You'll have to turn down you machine and work at the hole.... deposit some weld stop, let it cool.... then lay a little more weld down.... and continue with the short cycles. Eventually you'll close it up or make it worse LOL._________________Chris
Reply:yeah, thanks for the responses. Why is it i can run a bead where it's almost all the way flush but as soon as there's a gap i cant. I have figured out how to fill the holes but it looks like ****. I'm waiting on my damn gas tank.Thanks again. O and it's off the car, i'm fabbin it to sit how i want so i gotta test fit everything.
Reply:Butt welding exhaust tubing isn't as easy for a newbee as it looks. You need a slight gap good penetration but it must be consistent.  As you found out if the gap gets a little wide you'll have a hole. Make tacks every 90*. Unless you're very good at fitting the pipes your best bet is to use tubing that has one end expanded to slip over the tubing. This provides the easiest welding and fitting.
Reply:alright, makes sense. I was supposto get my tank like 2 weeks back and im' still waiting on it. Hopefully i can go monday and pick it up.
Reply:Tresi makes a good point about using slip over connections where you can.. even whe welding old to new... they sell a ton of adapters._________________Chris
Reply:Just keep at it.  Weld let it cool, add a little more.  It will look like crap, but you can fill the hole in time.  Bare wire is SO much easier and faster on exhaust.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Auto supply stores sell a tailpipe expander for about $40 that can make a short slip-over connection making that weld a lot easier. It slips into the pipe-turn a bolt on the end to expand just enough to slip other pipe in-just 1/4" would make a nice looking joint to weld and eliminate any gaps.
Reply:Those tailpipe expanders come in 2 qualities. The cheaps are used with hand tools and will just press out the crimp made by the clamps. The expensive ones seldom found in the parts store are used with an impact wrench to expand the pipe for a slip fit.
Reply:Welding gaps on thin walled tubing on exhaust is a  . Usually the gap shouldnt exceed the thickness of the metal you welding. Most of welding is preperation...
Reply:The hand tailpipe expanders can't expand the pipe enough to slip fit can it?
Reply:RED NECK WELDING:  beer can...coat hanger.
Reply:lol, i got it to all fit. I turned down the heat and lowered the speed. welds came out nice.
Reply:There you go Joe, it's not hard after a little trial and error. Some help on the forums is good too. Keep at it !John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:yeah, i finally got my tank. Wasn't wat i expected. It's a 2' by 8'' tank. For c02. Filled w/ co2.Doesn't even have the right adapter for my regulator
Reply:We are in the new chat if you need more help. Three of us in there now.John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:Originally Posted by iWeasel410The hand tailpipe expanders can't expand the pipe enough to slip fit can it?