Welding on Aluminized Steel Tubing.

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Hey everyone.I'm new to the forums and thought I'd ask for a bit of advice on something I was wondering.When it comes to welding on aluminzied steel tubing for a car exhaust, what should be done to keep the oxidation resistant traits of the steel?The tubing I'm looking at is a 16 gauge wall tubing. I'll most likely be using a Miller 110V model at home for the process and was thinking of using a stainless steel wire (hopefully .023) instead of a mild-steel so that the weld bead anyway would resist corrosion.I live in Winnipeg and this car is my daily driver all year round, winter included, so I would like to try and reduce the chance of the system being eaten away prematurely by salt and general abuse.If anyone can let me know how to weld aluminized tubing while keeping it's corrision resistance in check would be greatly appreciated.Thanxs for your help everyone
Reply:Aluminized is what it is. You can easily weld right through the coating, some grind off, some don't. Will it rust?? Yes. Any exhaust, even SS will rust out with salt on the roads. There is nothing you can coat the welds with that will last through the heat of the exhaust gasses. Spray on galvanizing will work for a little bit. But get the industrial strength stuff, not the cheap stuff.And then, after so much work...... you have it in your hand, and you look over to your side...... and the runner has run off. Leaving you holding the prize, wondering when the runner will return.
Reply:Can't be done. Weld it with anything you like but it won't make any difference. It will eventually rust where the aluminum coating is burned away where you made your weld. An exhaust system made completely of stainless will last an awfully long time. Will it be worth the extra cost. Only if you keep the vehicle for a very long time also.
Reply:Those guys are dead on man, stainless is the only way. I have lived in Wisconsin long enough to have tried it all, the salt always wins.Yup
Reply:IF I can, I remove the aluminum with a wire wheel.  If not.... I just weld it.  Stainless wire won't make the pipe not rust next to the weld.  I done a LOT of em.David