Well, the secret is out...

[ForcedFirebird]

Consider a flexible extension in line with the wastegate downpipe, otherwise it can be a headache to get things to line up. I decided against open dump this time and found myself having to loosen every exhaust related bolt, inlet and outlet at the turbo in order to properly line up the wastegate flange after it was welded up and it still wasn't perfect. I went 18 ga on the exhaust from the turbo because it endures the least heat stress but at the same time is subject to the most warpage if excess welding heat is generated to soon.

God gave me a wonderful brain I must admit. When the angle of the dump pipe merge turned out to be to narrow for the MIG nozzle, I fabricated a pencil size nozzle out of some hollow aluminum tubing just the right diameter and used some tape to insulate the tip. It worked well enough for me to fill in the gap without a pile of metal reaching to a wider area.

Here's how I weld a merge...

Step one, weld the ends of the pipes


Then wrap the weld around the outside of the merge


Then put the collector on and seal around





That was using a TIG welder - even harder than a MIG to get in tight spaces.

[3400-95-Modified]

Those TIG welds look nice. I wasn't crazy when I suggested that for headers

[carbon]

Thanks for showing how collectors are welded...

I have stared at pictures a long time without being able to see how the heck its done. Of course I don't know how to weld... so that didn't help either.

As far as the first post...

I signed up to this forum just to defend myself against the almighty Fiero's (no this doesn't included you Joseph :P)...

I know it was a long time ago now but those were definately the proverbial foot-in-mouth soldiers that were responding to that thread...

Carbon
1988 Fiero GT