Over the weekend I decided to tackle the project of welding up some pieces of the exhaust. It was a steep learning curve as I was using a HF band saw to cut the SS tube that I had (Did really well) and a HF stick welder.
The stick welder was a huge learning curve as you have to use the correct sticks (electrodes) at the correct amperage. I'm sure some of the experienced welders on the forums know this.
The welder I happened to use is in the link
https://www.harborfreight.com/amp-ac-120-volt-stick-welder-60768.html
I had to use this welder because the flux core welders do not get hot enough and I bought this welder a couple years ago anyway so I might as well put it to use.
Welding stainless requires good heat but low to mid amperage from what I have been researching.
The HB band saw that was used was the Chicago Electric Portable Band Saw. For some reason though this item is no longer available and I got lucky at a HB parking lot sale and bought it at clearance price but used a 20% off coupon to get it for a bit cheaper. I did find it on eBay though; in case anybody wants one. They replaced the Chicago Electric with a questionable Bauer one.
I bought the resonator and muffler along with the 10 foot tube and prebent 45 degree tubes from my man over at Blue Magic Performance Plus. I also had a few 90's kicking around too. The prbent tubes are from vibrant and honestly, if you can get them from some other supplier, I would recommend doing so because the quality of vibrant is not good for welding.
I measured up the long stainless tube along with the 45 Degree bend and the resonator to see what I was working with in measurements.
I wanted the resonator to be located before the hangers that way I didn't have to deal with a hanger breaking off at the resonator and creating a hole thus needing to replace it.
No I got to a point where I was frustrated at the 45 degree bends. I did not take too many pictures here because I was really deep in the moment on trying to get the bends welded. In the 9-5's we have a 45 degree bend going to a straight at about 8 inches or more then at goes right back into another 45 degree but there is an angle down to what looks like clearing the gas tank. While welding with the Arc welder (Stick welder) you need to make sure you are using the correct electrodes. I was using 6013 at first using the Amperage setting of 70. That was a bad idea because it started burning holes right into the vibrant tubes so I had to play with the settings quite a bit and change sticks just to get some decent results. After all said and done, my welds were finally done but I probably added so much weight to the tube do to filling the holes so much.
This was very frustrating but this is still my very first project with a stick welder and welding up an exhaust.
I needed to extend the pipe just a little more so I cut a 2 inch piece off of the long tube and then went on to weld it to the 45 degree bend and this is where I started noticing an improvement in the welds. I guess I was learning from my mistakes. Overall I was able to get most of the exhaust done until I realized that I neglected to get rods for the exhaust hangers. I stopped as i was getting to the muffler.
I pulled a ghetto fabulous because I really wanted to hear how quiet the exhaust was with what I was able to complete. I cannot say that I am disappointed though because it sounded much more pleasing than dealing with an open down pipe for about a month.
Putting it on went pretty smooth and on top of that right where I am putting the 90 degree bend, transitions smoothly to where I mocked up the muffler. For now this is what I have completed until this coming weekend where I can rig up some hangers that way i can get rid of the wire coat hangers that I had to use to tuck the tube up more.
I do have to say that this was fun and so far I would recommend this project to someone that is willing to learn new things, has at least intermediate flux core welding experience and is on a budget. Just ave tons of patience
So far, with the purchases of the exhaust pieces from my man over at Blue Magic Performance Plus and the prices he gets things for, and the GS 3in DP I purchased from someone on the forums I think it was, I am in the 600 dollar range using stainless steel. I think this could be reduced more if aluminized steel tube was used from turbo back.
I do notice a torque difference so far with what I have now and the spool up is a little better. I think I am mostly happy that I can finally hear the spool up and the BOV in this thing. Yes I did say BOV. I picked up one of these guys for pretty cheap form a guy on CL.
https://www.ecstuning.com/b-forge-p...GbJSOzWOOoobblW-9DjlpyxUPQIQP0iceIBoCnenw_wcB
Works well and I had to adjust it to where only a tiny bit of air can vent into the atmosphere. I do not have any check engine lights and I have not seen any stored since my last plug in.
I will follow up this weekend to get the muffler completed and keep you guys posted.