Stainless Stick Welding

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Need some advice. Buddy of mine wants me to weld a new muffler on his truck (2005 Tacoma) the muffler is a stainless steel magnaflow, I'm guessing the rest of his stock exhaust is regular steel.What rods do you think I should go with? I saw something about Lincoln Red Baron rods, also since its exhaust I'm figuring like a 3/32 rod? I'm pretty sure it'll be a regular steel to SS weld, but if it turns out to be SS to SS weld is there a different rod to use? I know not to use same tools to clean SS w/ that I clean regular steel with.Sorry for such a newbie post again, as usual, lol
Reply:A 308 or 309 would be the rod of choice.
Reply:3/32 rod is probably a little too hot. I suggest mig or tig.309 stainless filler metal is really good at joining dissimilar metals.
Reply:Originally Posted by jamesyarbrough3/32 rod is probably a little too hot. I suggest mig or tig.309 stainless filler metal is really good at joining dissimilar metals.
Reply:many years ago I did some SS stick welding and something you need to watch out for is the slag pops off the weld as it cools (I mean shoots off it like shrapnel)
Reply:Yea I read about the slag flying off at high speeds and to keep your mask on.Found some 308-16 3/32" rods, but gonna see what Airgas has in stock before I decide.I'd prefer to mig or TIG it but I'm not comfortable with my TIG yet and I don't own a mig.1/16" you think would be better? Also anything about these Lincoln Red Baron rods?309 would be best for SS to whatever the stock exhaust is?
Reply:I've used 5/64" and 1/16" stainless 316L rods. I don't know material thickness of a muffler but it seems the 3/32" rod would be too big. I'd use 5/64" from 1/4" down to 1/16" (with care) but 1/16" would be better for anything thin.I've seen 20 gauge stick welded with 1/16" stainless rods. But you got to be fast and weld down hill for that to work.The stainless rods I've used are super easy to restart so it's real easy to make lots of spot welds. You'd want that when welding thin material. Even if you make a nice long bead over the spot welds they will cool down your puddle and transfer heat between the metals you are welding. Also fit up needs to be good.Also stainless rods will work nicely on mild steel as well so I wouldn't worry about welding stainless to mild steel except that it will rust eventually.PS: Don't know what stick machine you have but your are going to run 1/16" rods on low amps like 30.Last edited by Pete.S.; 04-17-2013 at 05:23 AM.
Reply:Originally Posted by teknicsI'd prefer to mig or TIG it but I'm not comfortable with my TIG yet and I don't own a mig.
Reply:Originally Posted by smilexelectricI agree. If you can get your hands on some 1/16 stick electrodes that would be ideal but I am not 100% sure how they weld as I have no experience with them.