welding exhaust with a mig...

[chucked]

What size wire should I use to weld a car exhaust? this is a solid wire, gas welder, the same one monster garage uses. ESAB

[Aceman]

:confused:
I just used the .030 wire for my trucks exhaust. I didn't know it mattered what size wire, except you probably don't want to use the small stuff.

[chucked]

Originally posted by Aceman
:confused:
I just used the .030 wire for my trucks exhaust. I didn't know it mattered what size wire, except you probably don't want to use the small stuff.

well i would burn right through it with .035, I have .025 layin around somewhere, I welded a few things that were pretty thin with the .025, but not as thin as this exhaust...

[Aceman]

Really?? My exhaust was probably about 1/16" wall and it worked fine. Maybe yours is thinner. I used a Millermatic 175. What's the thinnest your welder is capable of doing? I think mine goes down to 20-22 gauge or something like that. I can make a pass across roofing tin if I go fast enough with the .030 wire.

[chucked]

Originally posted by Aceman
Really?? My exhaust was probably about 1/16" wall and it worked fine. Maybe yours is thinner. I used a Millermatic 175. What's the thinnest your welder is capable of doing? I think mine goes down to 20-22 gauge or something like that. I can make a pass across roofing tin if I go fast enough with the .030 wire.

I havent tried with the .025, with the .035 I couldnt get it adjusted to get a solid bead to slow it up, I will just have to work with it some more. Ive only been welding for 2 years, I have barely done anythign under 1/8" steel. I just assembled 12 plow skids for the NSA down here, they are made out of 1" steel and weigh about 150 lbs each, its kinda hard to burn through that stuff....

[brian350rx]

you can weld it with any size wire if you keep burning through it just keep repeatedly pulling the trigger with maybe a second in between (pulses)

[chucked]

Originally posted by brian350rx
you can weld it with any size wire if you keep burning through it just keep repeatedly pulling the trigger with maybe a second in between (pulses)

then it will look like sh&t

[brian350rx]

not if you do it right

[Aceman]

Originally posted by brian350rx
you can weld it with any size wire if you keep burning through it just keep repeatedly pulling the trigger with maybe a second in between (pulses)

That's news to me. As far as I know you just turn the heat down and maybe increase the feed a little. If I was you I would find some scraps as thin as your exhaust and practice until you can get it right. I usually do half moon shapes going from side to side, this has always worked well for me with the wire feed.

[400exdad]

Originally posted by brian350rx
not if you do it right

Thats right! Gas makes a big difference and you can't let the metal go "cold" before you hit it again.

[chucked]

i used .045! I made 2 welds, the first one I burnt through twice, but a very small amt, like the size of a bb, the second one, I just did little 1/4" long tack welds all the way around it, much better.

[AtvMxRider]

If you are buring threw it you need to adjust the heat. .035 is fine. I use it for eveything.

[chucked]

Originally posted by AtvMxRider
If you are buring threw it you need to adjust the heat. .030 is fine. I use it for eveything.

it was almost all the way down, about .75/10

[AtvMxRider]

Originally posted by chucked
it was almost all the way down, about .75/10

Well .045 is way to big. use a smaller wire and adjust your heat.

[chucked]

Originally posted by AtvMxRider
Well .045 is way to big. use a smaller wire and adjust your heat.


didnt have any, there was 6" of snow on the roads, I have a rwd truck, and Im impatient, **** it :)

[bulkdriverlp]

i use .35 for everything and never had a problem. i woud prolly use b,c heat range for exhaust and wire speed 3.5. thicker stuff like 1/4 and up i use heat range d and wire speed 4-4.5. but in order to weld on the highest heat range youll have to put in a 30 amp breaker cause if you dont itl pop a 20 after a couple minutes. plus its mutch safer too, cause ur ground wire may get hot from the amprage not flowing through as well. i just used mine today.