Hey everyone so had my first attempt at building a custom exhaust, and short story the first half didn't go to well my main goal in the end was to tig weld it nice and possibly post some pics but it ended up going wrong. I found my self having huge gaps and pieces with very poor fit up. If any one can guide me in some manner so that I'm able to get tight gaps and find the correct angles that would be great thanks.

 

You can go two ways really:

Buy little pieces of bends already cut/chamfered and essentially tape them together with minimal cutting or you can buy U/J-bends and go to town.

Now you understand why custom headers cost so much!

Do you have an angle finder/protractor?
How are you cutting the tubes (band saw/sawzall/chop saw)?

 

Didn't really use an angle finder, and I'm cutting all material with a band saw any tips tricks you pass my way would be great.

 

Post some pictures of what you got . . . masking tape and a sharpie go a long ways

 

use two straight edges on each face of the bend, that will help find the center point, then simply pivot off of that point for the desired angle. without this, you are likely to make an unsquare cut, which will result in an oblong tube opening, and horrible fitment to its mating tube

 

Use pie cuts to get the angle you desire.

 

A digital angle finder and cheap horizontal bandsaw are your friends. There is too much deviation in a hot saw.

 

Horizontal bandsaw and some good visualization/spatial geometry.

 

Buy a T bevel and angle finder. Use the t bevel to line up your next bend then place the t bevel on a flat surface and use the angle finder to tell you what the next bend degree is.