i actually started the exhaust today!

Hey guys,

I started a bit late as I had to do some chores and work on my wifes car, but i actually got something done today. It's not much but it's a start, I put together my first piece of mandrel bend that goes over the frame. I took two 90 degree mandrel bends and welded them to the collector flange. I did this because the headers exit parallel to the transmission crossmember. I considered grinding some room for the pipes but instead thought it would be better to go up and over the crossmember and run the exhaust parallel to the frame. This will not only look better because the exhaust will not be visible but it will also give me way more clearance when i either bag or lower the truck later. Anyways, let me know what you guys think. I'm also open to any tips on my welding based on what you see. I'm a total amateur. Thanks!

(the last pic is the other side so you can see what i mean about running into the crossmember, it's just enough to give me an excuse to do things the hard way)

It's a good idea to run the exhaust over the crossmember if you want to hide it and think you might need the ground clearance. Another idea is to get some thick walled tubing that is larger in diameter than your exhaust pipe and use said tubing to make tunnels in the crossmember, allowing the exhaust pipes to pass through the crossmember. But it doesn't really matter as long as the exhaust clears everthing and you design it so that it can be removed if you need to get it out.

good idea, i was trying to figure out what i was going to do on the next crossmember as I was thinking about going through that one. i figured i'd cross that bridge when i got there

i got the other one done guys, here are some pics and a preview of whats next. hopefully i can get some more done tomorrow night.

Cutting angles?

Joe,
What r u usin' to cut the angles of the pipes in the last foto?

BoB

do you mean the dumps? those are pre-fabbed; $25 each from summit, i couldn't build them for less then that

Feels good to get something done, dosen't it?.............looks good to me.

i worked on it some more last night didn't go well though, i got the position of dumps figured out, tacked it together, then put it in with out bolting it to the headers so i could eye up my angle and make sure it was ok (big mistake), i should have bolted it, instead i spent however long getting it all welded together and then tried to bolt it on. So the dump sits at a nice 30 degree upward angle. I decided to let it go for the night and put everything up at that point. no pics as the camera was dead, oh well.

if i get a chance to work on it later this week i think i will pull it off, chop saw the offending welds, then do my tack welds while it is bolted to the headers. this whole exhaust thing is a real headache, i'm tempted to give up and just slap my glasspacks on the headers with a slightly notched crossmember. I just have to keep telling myself the extra work will be worth it.

has anyone else here welded up their own exhaust before? I'm wondering if there is a better way then what i'm doing now. Right now i'm spot welding all the way around with a mig welder, flux core wire is all i've got also. it takes forever this way but if i do more then spot welds it burns right through. thanks guys.

joehalford01 said:

has anyone else here welded up their own exhaust before? thanks guys.

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I have. It just takes patience. And make sure that every part that is finished already is firmly bolted or hung in place, such as the headers and/or collectors. In the places that you intend to use hangers, fab those into the exhaust system as you go in order to hold that part of the exhaust in place while you move toward the rear. I only tack weld the pieces until the entire system is complete in the event that any changes need to be made. Then I go back and weld everything.

The welding stitch welding method that you are using should be fine. It's just a time consuming task. Relax and be patient.

No kiddin'!!!

joehalford01 said:

do you mean the dumps? those are pre-fabbed; $25 each from summit, i couldn't build them for less then that

Click to expand...

Joe,
No kiddin'! I'll ck it out... thanks for the tip!

BoB

Gastrick said:

I have. It just takes patience. And make sure that every part that is finished already is firmly bolted or hung in place, such as the headers and/or collectors. In the places that you intend to use hangers, fab those into the exhaust system as you go in order to hold that part of the exhaust in place while you move toward the rear. I only tack weld the pieces until the entire system is complete in the event that any changes need to be made. Then I go back and weld everything.

The welding stitch welding method that you are using should be fine. It's just a time consuming task. Relax and be patient.

Click to expand...

thanks for the advice gastrick, tacking it and building it all underneath actually does sound easier, i was trying to build each piece of it one at a time on a workbench. i end up crawling underneath the truck 100 times the way i'm doing it. also makes it hard to make changes as i go, i've already changed the layout 100 times in my head.