Question about exhaust welding

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Old 08-05-2010, 08:59 PM
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Question about exhaust welding




Didn't get a chance to ask the shop this question so here it goes...What size tubing do I need for the outlet coming to the red arrow 2.25' Inlet muffler.
What size inlet tips do I need for the blue arrow 2'' outlet.

This is what I was thinking so correct me if I'm wrong...

Outlet tubing (2.5'')----->(2.25") Inlet muffler
Outlet muffler(2")------->(2.25") Inlet tip

Last edited by Grizzle; 08-05-2010 at 09:04 PM.
Old 08-05-2010, 09:34 PM
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No. Just keep them the same size. The shop will expand as needed to have it slip right over.
Old 08-05-2010, 09:38 PM
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are you buying everything? It really depends on the shop. When I built my exhaust, I bought everything to match the inlets and outlets. All the tips I purchased slipped over the muffler ends and if they didn't, I used a pipe stretcher to make it fit.

The same goes for the inlets. I buy the same size and expand the pipes to fit over. If the shop has a really good welder, then they can butt weld without expanding.
Old 08-05-2010, 09:40 PM
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I hated butt welding. Unnecessary and was a waste of my time. I hated when people asked for it.
Old 08-05-2010, 09:45 PM
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I hear you, unless you are showing the car with polished SS, it's totally unnecessary. I'm self teaching myself to weld and it's been fairly easy to weld 2 overlapping pieces of 16ga steel.
Old 08-05-2010, 10:11 PM
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Originally Posted by KN_TL
are you buying everything? It really depends on the shop. When I built my exhaust, I bought everything to match the inlets and outlets. All the tips I purchased slipped over the muffler ends and if they didn't, I used a pipe stretcher to make it fit.

The same goes for the inlets. I buy the same size and expand the pipes to fit over. If the shop has a really good welder, then they can butt weld without expanding.
I'm gonna check with the shop tomorrow and see what they say. I was planning on buying everything unless the shop gives me a better deal.
Old 08-05-2010, 11:31 PM
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Originally Posted by KN_TL
I hear you, unless you are showing the car with polished SS, it's totally unnecessary. I'm self teaching myself to weld and it's been fairly easy to weld 2 overlapping pieces of 16ga steel.
Next step is to make your welds look better than the machine welds.
Old 08-10-2010, 07:24 PM
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Originally Posted by Grizzle



Didn't get a chance to ask the shop this question so here it goes...What size tubing do I need for the outlet coming to the red arrow 2.25' Inlet muffler.
What size inlet tips do I need for the blue arrow 2'' outlet.

This is what I was thinking so correct me if I'm wrong...

Outlet tubing (2.5'')----->(2.25") Inlet muffler
Outlet muffler(2")------->(2.25") Inlet tip

Hey man is this set up for a TL or TL-S? I have a 07 TL-S and I know the stock cans are pretty short. Wondering if this would fit my car.
Old 08-10-2010, 08:07 PM
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Originally Posted by JackSampson
Hey man is this set up for a TL or TL-S? I have a 07 TL-S and I know the stock cans are pretty short. Wondering if this would fit my car.
This is for a base TL. I'm not sure if it would work. I believe there is some members on here that have done custom exhaust.
Old 08-10-2010, 08:12 PM
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The 5"x8" oval in 20" overall length would prob fit but I'm not sure what the stock piping for a TL-S is.
Old 08-11-2010, 06:27 PM
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The muffler fits fine its what im running on my TL
Old 08-12-2010, 03:13 PM
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Originally Posted by subinf
Next step is to make your welds look better than the machine welds.
Another option is grinding. If you are planning to paint the exhaust after welding, then use a grinder to smooth out the peaks and valleys of the weld bead. Granted, be careful to not remove too much of the bead to make the weld prone to crack.

In my old hotrod days with my Camaro, this is what I did.
Old 08-12-2010, 09:26 PM
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I did that too. If I needed something to look really nice I'd just use the TIG welder but that took a lot more time. Smoothing out with a grinder is a good alternative.
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