Exhaust Headers

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My first real project.  The reason I took up welding as a hobby.  Had to modify some longtube headers to fit my chassis.  The welds came out "meh".  It was really difficult to get proper fit-up, this being the first time I have ever done this.  They may be ugly, but they will work for what this project is.They are the two on the right side in this pic
Reply:not too bad for a hobbyist :]
Reply:Oscar, You picked a tricky first project. Welding like anything you will get better with time and practice,practice. Looks good for a first project.
Reply:Originally Posted by powerOscar, You picked a tricky first project. Welding like anything you will get better with time and practice,practice. Looks good for a first project.
Reply:I will add a bit, not to scare your or put you down whatever.  I will also add I am a hobby welder.But in the first pic the welds look cold and lot of cut and weld with small pieces to make them fit.  (what I would do right now also, just lack some of the bending stuff whatever)  Otherwise looks good, even with the multiple welds and alot of parts it looks good.  Just looks like a cold weld.The second pic,the weld looks cold again, fitup on the pieces closet looks great.  They appear to be touching or almost, the other, to big of a gap.  However for exhaust you can fill that gap welding and it will be fine.  Try turning the heat up some and finish it.  Post some pics then.You should get to much or to little heat, to fast to slow, etc...  All this said, looks great, just need more practice, and first time that is good.  Some advise is good though.
Reply:Originally Posted by kcb37I will add a bit, not to scare your or put you down whatever.  I will also add I am a hobby welder.But in the first pic the welds look cold and lot of cut and weld with small pieces to make them fit.  (what I would do right now also, just lack some of the bending stuff whatever)  Otherwise looks good, even with the multiple welds and alot of parts it looks good.  Just looks like a cold weld.The second pic,the weld looks cold again, fitup on the pieces closet looks great.  They appear to be touching or almost, the other, to big of a gap.  However for exhaust you can fill that gap welding and it will be fine.  Try turning the heat up some and finish it.  Post some pics then.You should get to much or to little heat, to fast to slow, etc...  All this said, looks great, just need more practice, and first time that is good.  Some advise is good though.
Reply:This is a piece of a short weld I just made that I ended up cutting out of the last piece of tubing.  I filed it down a bit to reduce the glare from the flash on my phone's camera.  As you can see, I'm getting pretty good penetrationI had to cut this out to make a little "window" to get the very last tube welded;  half from the inside through the "window", and then the window will get patched up to finish the weld, and  the headers as a whole.Same weld, but on the actual header pipe Last edited by Oscar; 08-27-2012 at 05:56 PM.Reason: added pic
Reply:Great first project.Being new... have you read turbocad6's header thread? It might give you some ideas and insight. http://weldingweb.com/vbb/showthread.php?t=45112
Reply:I think I had seen that a while back.  Just didn't remember to look it up.  That jig is cool.  I should probably build something similar for if and when I decide to ditch these for SS headers.
Reply:If looks aren't going to be a big issue those don't look bad, and the construction is not bad.  Nothing wrong with leaving those on the car for several years.  Not an easy project to start with, but you have done good.  Like anything else, just takes practice.
Reply:Originally Posted by kcb37If looks aren't going to be a big issue those don't look bad, and the construction is not bad.  Nothing wrong with leaving those on the car for several years.  Not an easy project to start with, but you have done good.  Like anything else, just takes practice.
Reply:Done.  Last few pics:Inside of tube to be weldedCover that will go over the window:Inside of tube welded and ground down just enough to not hinder exhaust flowviews of tube welded up with coverFinished headers ready to be sandblasted and painted tomorrow.
Reply:OK, first off most guys want a header that not only works good but looks good also I realize this is your first exhaust project but this is how we learn by watching andlistening to guys that do this all the time......Instead of three 1 in pieces  cut one 3 inch piece  or even a whole section......Much better looking and actually easier to weld..If your not real familiar with tig use OA  and a  OO tip....might be easier for you...Fixtures are a must for repeatability.......and it just makes things easier........  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock
Reply:Originally Posted by B_COK, first off most guys want a header that not only works good but looks good also I realize this is your first exhaust project but this is how we learn by watching andlistening to guys that do this all the time......Instead of three 1 in pieces  cut one 3 inch piece  or even a whole section......Much better looking and actually easier to weld..If your not real familiar with tig use OA  and a  OO tip....might be easier for you...Fixtures are a must for repeatability.......and it just makes things easier........