Another Turbo Header Build

[Mike E]

.035" 308 filler on the tubes and inside of the flanges. The outside of the flanges is silicone bronze.
The machine is set for 70 amps for welding the tubes, but I throttle the pedal a lot. I probably weld closer to 60 amps
Red 1/16" tungsten
#6 gas lense with torch argon at 15 cfh, purge argon at 5 cfh
I don't use solar flux. If you have two bottles and two flow meters, purging is much easier.
I don't wear any breathing protection and I've never had any issues.

 

[norbs]

1/16" 308 filler on the tubes and inside of the flanges. The outside of the flanges is silicone bronze.
The machine is set for 70 amps for welding the tubes, but I throttle the pedal a lot. I probably weld closer to 60 amps
Red 1/16" tungsten
#6 gas lense with torch argon at 15 cfh, purge argon at 5 cfh
I don't use solar flux. If you have two bottles and two flow meters, purging is much easier.
I don't wear any breathing protection and I've never had any issues.

Thanks, i guess I need better ventilation in my shop, or I am over sensitive to it. I use a Y splitter, seems ok except the duct tape seems to get too hot and looses its stick. So the whole flange is welded with silicone bronze on the outside?

 

[Mike E]

The argon is heavier than air, so it should settle on the floor. What do you clean the tube with, maybe that is giving off fumes. I use acetone or startung fluid (either).

 

[Dusty Bradford]

Nice write up. For welding the tubes together I use mig wire as my filler rod. I take about a 6ft length of mig wire. Fold it in half, clamp one end in a vice and put the other end in my cordless drill. Spin the drill over until you get a nice tight strand of filler rod. It works great for me.

 

[Mike E]

Nice write up. For welding the tubes together I use mig wire as my filler rod. I take about a 6ft length of mig wire. Fold it in half, clamp one end in a vice and put the other end in my cordless drill. Spin the drill over until you get a nice tight strand of filler rod. It works great for me.

I fixed my above post, I used .035 stainless filler for the tubes. I tried to straighten mig wire, but I can never get it perfectly straight and I constantly have to fight to keep it near the puddle. But, I wasnt' folding it over. I bought 1 lb. of the .035 filler and It's enough to last me for about 5 sets of headers.

 

[J-B Racing]

we are going to change this thread to

( weldingtipsandtricks.com ).............lol...................good info..

 

[norbs]

Here is a nice little product Mike should look into getting.

 

[norbs]

The argon is heavier than air, so it should settle on the floor. What do you clean the tube with, maybe that is giving off fumes. I use acetone or startung fluid (either).

I am using acetone it stinks a bit, but once it drys up its gone. I bought a table fan I should be ok now to blow the fumes away. I hope anyway..

 

[Mike E]

If you have the fan blowing on you while you weld it will blow the shielding gas away and your welds will be contaminated.

 

[Dusty Bradford]

Yep. Turn the fans away from you when you weld. I have an a/c vent right above my welding table and it messes with me. I'm going to move the table elsewhere rather than having to turn the a/c off.

 

[Dusty Bradford]

I fixed my above post, I used .035 stainless filler for the tubes. I tried to straighten mig wire, but I can never get it perfectly straight and I constantly have to fight to keep it near the puddle. But, I wasnt' folding it over. I bought 1 lb. of the .035 filler and It's enough to last me for about 5 sets of headers.

Folding it over and spinning it in a tight weave has always worked for me. I need to pick up some small wire like you have and try that.

 

[Chuck Leeper]

If you have the fan blowing on you while you weld it will blow the shielding gas away and your welds will be contaminated.

I had to divert the fan flow from the welder.. Both the intake and exh side. Welder sits so close to the bench, it was causing issues.

 

[dr_frankenstein]

why the mig wire? whats special about using that over regular filler rod?

 

[Mike E]

It's cheap and easy to find in small diameter. I had to order the .035 filler because my local welding shops didn't stock anything smaller than 1/16".

 

[norbs]

Tig tip If you want to join 2 pipes together and you have no way of holding them tight. I use a hose clamp and cut some oval holes in it to get the tacks in, with the pipes butted tight.

 

[Chuck Leeper]

A couple items for the "welding tips/triks"....
I use MEK to clean the pipe. Note: mandrel bent pipe will usually have a lube residue in it from the bending process. Once the pipe is hot, that lube will run. I clean the pipes their entire length, to prevent weld contamination. I do this B4 I cut the pipe. That way, the cutting dust isn't stuck in the oil.
I use a scotchbrite to polish both the inside and outside of the ends that are to be welded.
The pipe is then cleaned again w/ MEK, and a rag. [Someone says "no paper towels".]
I also clean the filler rod w/ MEK.

 

[Mike E]

Long overdue update. I have the headers mostly finished, just need to build the crossover.

 

[charlief1]

Shame on you Mike! A ferd blue drive shaft? Almost wish I was still in TN so I could come over and work on my headers.

 

[Squid4life]

First thing I thought was how many folks will see that driveshaft every time this car leave the line dragging its bumper!!!!

 

[Squid4life]

Mike, you own a GoPro? We may have to take up an offering to put one on your car!