Fail!!!

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I have these headers that came off my 71 Scout that are..............messed up. The right one has a crack 2/3'rds the way around at the collector and one of the lower tubes is rusted through and has a former hack repair. The left one is cracked at the 4-into-1 collector entrance. I believe they are at least 30 years old, maybe older. So I decided to see if I could fix them.......let me start by saying that I don't believe that there is much material left to fix and I was using this for practice and skills building.So hear is what happened today.......I was able to repair the large crack around the collector flange eventually. Because of the age of the cracks and holes, the steel around the problems is VERY THIN. So through a series of "tack" style welds, I was able to build enough weld to close the crack by welding inside and out of the crack. Although it was repaired, it required a lot of grinding to dress the repair because of the multiple tack welds. I believe that my main problem was my wire, I was using .035 FC and it was just to hot, and kept blowing through. I will be getting gas this week and will pickup some .023 wire to try to finish the repairs.No pics for now, will get some tomorrow. As for the tube repair, I think that I will have to replace a section of the tube to fix it, rather than try to make a patch for the hole.Either way......it was a good afternoon of practice and learning.  HF 180 amp/240 volt Mig (cap mod)1987 Harley FLHTP (project)1990 F350 XLT Lariat S/C dually1990 S&S 11SC Cabover Camper2011 Ford Ranger S/C XLT
Reply:FC wire is just the wrong process for that.   you need MIG.  .030 or .023 wireTiger Sales:  AHP Distributor    www.tigersalesco.comAHP200x; AHP 160ST; MM350P,  Spoolmatic 30A; Everlast PowerTig 185; Thermal Dynamics 60i plasma.  For Sale:  Cobra Mig 250 w/ Push-pull gun.  Lincoln Wirematic 250
Reply:Soutthpaw definitely hit that on the headFluxcore is not for thin material unless your good and desperateand sometimes not even that helpsBest processes for this type of repair work would be O/A , Tig , Mig I know DJ can't make it to wel o rama( which is to bad  ) but will you be there desert scout you could learn some thingsLast edited by killdozerd11; 05-03-2013 at 10:17 AM.Backed my CATMA over your CARMA oops clusmy me  What would SATAN do ?? Miller Trailblazer 302 AirPakMiller Digital Elite  Optrel Welding HatArcair K4000Suitcase 12RC / 12 VSHypertherm PM-45Rage 3 sawRusty old Truck
Reply:I'm learning new stuff because of your experience... Thanks for posting.Qualified & experienced at welding scrap metal
Reply:Originally Posted by killdozerd11Soutthpaw definitely hit that on the headFluxcore is not for thin material unless your good and desperateand sometimes not even that helpsBest processes for this type of repair work would be O/A , Tig , Mig I know DJ can't make it to wel o rama( which is to bad  ) but will you be there desert scout you could learn some things
Reply:Originally Posted by rexcormackActually, the proper way to repair those headers would have been to throw them in the trash and replace them with a set of stock cast iron manifolds. I'm assuming it is a stock IH V8 so the headers probably gave you about 1/2 hp gain.
Reply:I know, I know.....I was just bein lazy. I have some .030 FC that probably wouldn't do much better. I'm planning on picking up some gas this week along with some .023 to play with.As for weld-o-rama, just got home from a pre-planned weekend of fixin stuff at my mother-n-laws place. We have our hands full between my 84 year old Mom and her 79 year old Mom. Both Dads are gone and we are the closest out of the families to them. Believe me....they are both a handful at this phase.HF 180 amp/240 volt Mig (cap mod)1987 Harley FLHTP (project)1990 F350 XLT Lariat S/C dually1990 S&S 11SC Cabover Camper2011 Ford Ranger S/C XLT