Plasmatron To The Rescue

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Yup, it is actually a welding thread.  The project has only just begun.Last time out, I almost succumbed to CO fumes.  My exhaust has leaked since I bought the truck, and it's finally time to fix it.  In the Winter it will almost kill you.  The flanges were welded to the pipe sometime in the past by the previous owner I guess.  They probably never fit right.  It's now a matter of either tweaking the pipes, or slicing them and rewelding them.  There was no good place to remove the pipe, so I had to cut it.  All the joints from the manifold back to the tailpipe have been welded in a previous life.  MORONS.  Broke the stud off in the manifold  Broke it flush  So, like I've done before with the cabover, I blasted it out with the plasma cutter.  60amps.  This was a real nail biter.  I'm under the truck, barely enough room for my noggin with the stupid welding helmet on, and way off to the side of the actual hole.  Hard to see.  So........place the torch directly in the center of the stud, try to align it properly, and pull the trigger.  It will only cut the stud, not the cast iron/steel.  Why??  Dunno, but I've found that it does.  I didn't have a good enough view to do a swirly to clean out the remainder of the stud, so I left it as is.  I can clean it up with a die grinder.  This technique is a life saver.  I was lucky to stumble on it a few years back.  It was born of desperation when I first did it, and still is the last resortOnly caution......make sure you have wet rags behind your punch-out, it keeps the O2/slag from lighting your favorite truck on fire"Any day above ground is a good day"http://www.farmersamm.com/
Reply:Now, if you'll excuse me................................."Any day above ground is a good day"http://www.farmersamm.com/
Reply:Oh oh.. I see in my crystal ball someone  approaching...my god! it's jim colt
Reply:Lord help us, it's beer night! GravelThe difference between theory and practice is that in theory there is no difference.
Reply:Finally got around to fixing the flange today.Was in pretty bad shape.Ground out what I could.  A lot of it literally just fell out.  Lot of fumes were getting through this."Any day above ground is a good day"http://www.farmersamm.com/
Reply:I was able to do some shrinking, and adjusting, to make the flanges fit square to the exhaust manifold.  Then I did my best to close up the gaps, and get it ready to install.I CAN'T DO MIG FOR CRAP, SO......................................I just stacked a lot of metal to fill the gaps, and called it good.  I figure it's maybe a bit better than what had been done to it in its previous life.  Was real interesting to run MIG.  Haven't used it in more than 2yrs.  Bad as I do with it, it'll be another 2yrs before I can bear to pick it up againLeast it's airtight, and exhaust tight.  Biggest thing was.........no burn through."Any day above ground is a good day"http://www.farmersamm.com/
Reply:Originally Posted by farmersammI was able to do some shrinking, and adjusting, to make the flanges fit square to the exhaust manifold.  Then I did my best to close up the gaps, and get it ready to install.I CAN'T DO MIG FOR CRAP, SO......................................I just stacked a lot of metal to fill the gaps, and called it good.  I figure it's maybe a bit better than what had been done to it in its previous life.  Was real interesting to run MIG.  Haven't used it in more than 2yrs.  Bad as I do with it, it'll be another 2yrs before I can bear to pick it up againLeast it's airtight, and exhaust tight.  Biggest thing was.........no burn through.
Reply:Originally Posted by farmersammI was able to do some shrinking, and adjusting, to make the flanges fit square to the exhaust manifold.  Then I did my best to close up the gaps, and get it ready to install.I CAN'T DO MIG FOR CRAP, SO......................................I just stacked a lot of metal to fill the gaps, and called it good.  I figure it's maybe a bit better than what had been done to it in its previous life.  Was real interesting to run MIG.  Haven't used it in more than 2yrs.  Bad as I do with it, it'll be another 2yrs before I can bear to pick it up againLeast it's airtight, and exhaust tight.  Biggest thing was.........no burn through.
Reply:Definitely not on par with your regular stick welding weldments... ... but if it holds, it is good enough!
Reply:Originally Posted by soutthpawTry doing a weave over the top of all those stringers.  Will look a lot better.
Reply:I'm curious why you think it is you have so much trouble with mig? Most think it's easier and it's what I use for most things because it's easier for me. What wire and gas do you use? I don't see anything really wrong with what you did there since old exhaust is hard to weld with any process.Yeah, I know, but it'll be ok!Lincoln Square wave 255Miller Vintage mig30a spoolgunThermal Dynamics Pacmaster 100xl plasmaSmith mc torchEllis 1600 band saw
Reply:Originally Posted by welderjI'm curious why you think it is you have so much trouble with mig? Most think it's easier and it's what I use for most things because it's easier for me. What wire and gas do you use? I don't see anything really wrong with what you did there since old exhaust is hard to weld with any process.
Reply:The heater intake is just a few inches from the pipe on the right side of the engine compartment.  So it's either freeze with the windows open, or heat the cab till you can't take the fumes anymore, then open the windows to get some fresh air"Any day above ground is a good day"http://www.farmersamm.com/
Reply:You might do better MIG welding if you just close your eyesJohn
Reply:Might be an improvementAnyhooooo...........she's up and running, NO LEAKS JUST DON'T LOOK UP UNDER THE MOTOR(did find some 3" flex pipe, at Oreilly of all places)"Any day above ground is a good day"http://www.farmersamm.com/
Reply:It works for me sometimes.  Any I'm glad you're not getting low on CO any more.John
Reply:Originally Posted by farmersammMy problem is that I'm used to running Flux Core, and Stick.  You drag with both processes.  I can't wrap my mind around pushing.  Mostly because I don't have a good clear view of the puddle, what with the nozzle in the way.  So.........I drag it, and as you know, you get funny looking flattish beads when dragging.  I have to learn how to push to my satisfaction.
Reply:At the risk of sounding ignant. . .how come you didn't get a reducer and then mig or tig that in place?
Reply:You don't sound ignorant at all.  I'm the one who's ignorant..........I can't run MIG for crap.  (read further up in the thread)  You're looking at around 4ish MIG beads stacked one on top of the other to close the gap.Reducer?  Naw, just seal it up, and call it good.  Been running ok like this for over 5yrs.  Got about 25 bucks in a flex pipe, and some hardware, to put it back on the road."Any day above ground is a good day"http://www.farmersamm.com/