When you tig exhaust tube to a muffler or resonator such as:



How do you deal with the gap between the outer diameter of the exhaust tube and the collar on the muffler/resonator?
I was using 1/16” filler, starting on the exhaust tube and working toward the end of the collar to get a tack. The filler builds up until it reaches the collar to form a tack. Once I have 4 tacks, I was starting on one of the tacks and working around toward another. It gets the job done but at times is a little messy. I often get a cold weld on the tube and have to go back and re-weld without filler. I guess I just need more practice.

Anyone have a cleaner way?

 

Drop some filler on one side, then the other and bridge the gap. Easy peasy!

 

try a 3/32nd filler instead

 

if you have a gap, shrink the metal down around the circumference until you have a tight fitup.

dont just run a larger filler rod LOL.

 

How do you shrink down the metal?

 

torch & wet rag?

 

Hammer.

 

might want to try a bead roller and roll a bead on the tube that slips into the resonator...its quick and easy and makes for a nice fitup

 

Sweet Idea! Just cut the pipe as close to the top edge if you can. I personally don't like to "fill gaps". I would rather work more on the fitment. An ounce of prevention is worth a pound of cure, is how I analogize it anyway. Fit it up well, and it welds easy. Torch and a wet rag is good, but I prefer a bucket.

 

hammer, pliers whatever your vice.... just something to make both ends the same size (or a tight slip fit) to get a good weld down.

 

Yup. Has never failed.