Finally welding the exhaust
 

I decided to take a week off and catch up on things around the house and really focus on the car. I have been stuck on the exhaust, so I decided to put in some serious hours this week. I started by practicing a lot and working out the back-purge settings. I figured if I practiced 4-5 hours it would really help. Well I figured out more like a 100 hours to get even moderately proficient. Finally, I just decided to jump in both feet and get something done. There is no better way to get experience than just get the experience

https://i.imgur.com/EJoZl3Ll.jpg

You can see there is no sugaring on the inside of the tubes after welding with a purge. This was my main goal and I was happy about that.

https://i.imgur.com/sgelKnwl.jpg

Here is an assortment of photos showing the in-process work. You can see the Kapton tape used to seal the un-welded joints in some photos. I got this idea off the Burns stainless website and it was a good idea.

https://i.imgur.com/b4CWOqCl.jpg
https://i.imgur.com/gie7B61l.jpg
https://i.imgur.com/AX9nU0ql.jpg
https://i.imgur.com/xI9aqqol.jpg
https://i.imgur.com/YLL2sQtl.jpg
https://i.imgur.com/8TVeA5Ol.jpg
https://i.imgur.com/IIVTkiel.jpg

Overall my technique is improving but I told someone I go between skillful welder and 5 year old at the drop of a hat. Here is a photo showing the welds are more-or-less OK but the technique isn’t consistent. I think I also need to work on my patience. I need to slow down and let things cool to minimize the oxidation, which definitely wasn’t done in this photo.

https://i.imgur.com/tpPaEQJl.jpg

Tomorrow I start on the X-pipe. It has about 150 inches of welding, so I will probably empty the second argon bottle and move to the third.
Next up I am going to add a door in the trunk floor. I spent a little time on the computer figuring out what it might look like. For simple things I am finding a 3-D model really helps because you can rotate it around and play with the design. I still need to drop the tank to start on this after the exhaust is finally welded.

https://i.imgur.com/7mLNeDOl.png

I am going to try to get out to Goodguys this Friday but hope to get more done over the next couple days and the weekend and post up some more images. Thanks for looking!

Looks better than my stainless TIG welding !

I think you're doing great.

Exhaust is welded finally!
 

Having a week off helped a lot. There were so many things to do around the house, but I focused mostly on getting the exhaust welded so I could move on. I had a couple of small breakdowns on the welder that I had to stop and fix. The gas solenoid was leaking and the post flow timer was shutting off early. The solenoid was a trip across town to Grainger and the timer was a couple of hours trying to figure out how to wind up this little clock spring and get it all put back together without pieces flying out. Afterwards the welder purred like a kitten. I should have fixed those long ago but the expensive argon back purge finally motivated me!

https://i.imgur.com/1ldRtjjl.jpg

I laid down some clean paper to keep my rusty table away from the stainless and taped all the joints with Kapton tape. Then it is just remove the tape and weld one joint at a time. I still have a lot to learn but I feel like it came out fine as far as strength goes.

https://i.imgur.com/efJgbLUl.jpg
https://i.imgur.com/NejvtANl.jpg
https://i.imgur.com/qIRNWwWl.jpg
https://i.imgur.com/FrxVy5ol.jpg
https://i.imgur.com/fVPlKs3l.jpg
https://i.imgur.com/RobV7mel.jpg

I ended up using almost two full tanks of Argon for the whole exhaust, partly the solenoid leaking and also I just move slower than a real welder!
The overall setup is fairly heavy and I don’t think my original muffler hanger idea is strong enough. I am planning to copy this idea from Detroit Speed, but didn’t get the parts, or get it properly figured out yet.

https://i.imgur.com/eNmg1dYl.png

I moved on to the fuel pump access cover. After lowering the tank I realized I had to grow the size a little bit and that took some time. I have it figured out now, but didn’t have a wide enough piece of metal to cut it from and the metal store was closed. I will pick some metal up on Monday.

https://i.imgur.com/bTtzRhdl.png
https://i.imgur.com/o1MMz08l.jpg

I have this old lathe I use for spacers and whatnot. It has always had a bad gear in the change box. I took a short diversion to get that removed and the gear on order. It was sort of a simple/fun way to wrap up the weekend.

https://i.imgur.com/qor99X0l.jpg
https://i.imgur.com/lY1x1b1l.jpg

Next week work on the fuel pump access panel and think more about the muffler hanger final solution.

Scott

You're welding looks good to me, Scott. I'd be happy if I could lay down welds like that. Good job on the exhaust!

I agree great fab work and maybe taking a week off is a good idea to get some stuff done around the house and car.....maybe just the car:yes:

Looks great :hail: Is that a corvette sway bar link on the DSE exhaust pic? huh?

Michael

Thanks for the kind words guys.
Chief I think you are correct that looks like a C5 Corvette link. I know there are other designs but that seems like a good place to start. Thanks for spotting that.

Scott

They are. The part number is 20822934 for them.

Thanks, great info. I will pick up a couple and see how they work out.

Scott

Fuel Pump Access Door Progress
 

I got a pretty good start on the fuel pump access door this week. I decided I liked the shape of the sketch and rough cut the opening. I put the tank up to make sure I have access to everything and it looked pretty good.

https://i.imgur.com/Y6kBGjyl.jpg
https://i.imgur.com/2ZeKiSrl.jpg

Using the sketch I cut my template out of 11 gauge material for the door frame, hacked it out and sanded it to shape. I pre-drilled the .125” pilot holes for later.

https://i.imgur.com/bhoFj3yl.jpg
https://i.imgur.com/G3n215ul.jpg

After trimming the frame, I cut the cover out of 18 gauge and rolled some stiffening beads, then match drilled the cover so everything will line up. I don’t know what I was thinking, this door has 24 fasteners. My friends were joking that it will be easier to take the gas tank out than take out all those screws. After taking it apart a couple of times they may be right.

https://i.imgur.com/oIzljBul.jpg

With all the holes drilled and tapped, I put the door frame in the trunk and started final sanding the trunk floor to shape until it fit pretty well. I only had time to get it tacked in place this weekend. I put the door on just to see how it fits and I think it will fine. After looking it over I may wait and weld this from the bottom while it is still on the rotisserie. I think that will be easier and will provide a better looking result.

https://i.imgur.com/KTEutazl.jpg
https://i.imgur.com/7MS2BtXl.jpg

I spent a little time figuring out how far to cut down the trunk hinge braces. The height is about right but the angle is wrong so I need to work a little more on those.

https://i.imgur.com/BXUHkCVl.jpg

Next week I will be working in the trunk area to finish up some of the fuel system and differential vent system ideas. I will move back to the exhaust hangers when the fuel line, and brake lines are worked out.