Downpipe completed *pics*
 

So I need my downpipe welded to my cast exhaust housing so I can keep the internal wastegate. I go to the local muffler shop and they say "You cant weld mild steel to cast, it will never hold." So I call up a welding shop, their ad in the phone book says "If it's metal we can weld it!" Sweet, guess this guy can weld anything I need. Call him up and he says that same thing. I tell him that I've seen if done before and he gets pissed and hangs up on me ::) Guess I'm gonna have to fluxcore the ---- out of this and put some extra metal in to fill the gap. A little garrison girth like Jeff recommended should help. Basically every shop in Madison with a welder is too ----- to weld this ----. And I'm gonna do it with the crappy fluxcore, wtf is wrong with people?

Here's a quick pic of what I have so far (Don't hate because you're jealous of my sexy welds)

http://img231.echo.cx/img231/1756/downcrap3xv.jpg

update:

Got the downpipe finished. I still need to install the WB O2 bung but that will be cake. I'll probably just put it one foot away from the turbo. On with the pics of the god damn sexiest downpipe you will ever see ;) Yes I know I suck at welding. It is airtight though, and that's all I care about. Give me a break, this is my first downpipe ever.

http://img25.echo.cx/img25/5954/dp18kw.jpg

http://img25.echo.cx/img25/3824/dp20vf.jpg

http://img25.echo.cx/img25/509/dp30rk.jpg

Re: NOBODY IN WI CAN WELD! *rant*
 

hahahah ford turbos own u
nice welds btw

Re: NOBODY IN WI CAN WELD! *rant*
 

------ Ford... I'm about to own it with the fluxcore.

Re: NOBODY IN WI CAN WELD! *rant*
 

heres a trick man
put the thing on high and only weld on the cast and let the weld drip onto the pipe
try not to touch the soft metal or ull burn through
and if u keep the weld liquid it wont look like birdshit

Re: NOBODY IN WI CAN WELD! *rant*
 

^^^ exactly. Just build up the weld on the cast and then once it gets pretty close then turn high otherwise if you have it low on the speed it's just melt that tubing. Muffler shop...Jargon you disapointed me. This is HMT!! lol jk Plus I can weld and I'm in WI! If it's metal I weld it with my trusty fluxcore.

Re: NOBODY IN WI CAN WELD! *rant*
 

Thanks for the input guys. I think I'll feel better about this after I weld some more.

Re: NOBODY IN WI CAN WELD! *rant*
 

even though you'd get more out of doin it yourself, i myself can't wait and i don't have the time or patience to learn.... when i would have called somebody i would have said look i know it won't hold, but can you weld this up... its business for them and they probably just didn't want you coming back to them with it broken

Re: NOBODY IN WI CAN WELD! *rant*
 

Yeah you won't feel better when that ---- cracks in half on you. Its hard to weld mild steel to cast iron because they expand at different rates. You need a rod that is designed specifically for this application check out a good welding store in your area. You might be better off brazing them together

Re: NOBODY IN WI CAN WELD! *rant*
 

Oh my GOD! You may want to look into having someone do that for you besides the guys you called. I myself have done that with no problems and Josh (Hotrex) does it more often than not. You really need a gas mig to get it to penetrate and stick well though.

Re: NOBODY IN WI CAN WELD! *rant*
 

i did exactly what youre doing, chipped it off witha chop saw and welded it with fluxcore, and then i cut pieces of metal to cover the gap and then welded ot shut, then went over all the welds and it didnt leak, looked pretty shitty cuz fluxcore sucks ass, but it worked

Re: NOBODY IN WI CAN WELD! *rant*
 

yput some little plates inbetween thoes gaps insted of trying to fill them up with wire. if your not already.

Re: NOBODY IN WI CAN WELD! *rant*
 

I'm sure the only reason the welders didn't want to weld it is so that they wouldn't be liable for it breaking in half. Hope it turns out alright for you though.

Re: NOBODY IN WI CAN WELD! *rant*
 

weld it real hot and then let it cool in a bucket of sand.

Re: NOBODY IN WI CAN WELD! *rant*
 

Yeah you cant fill that in with wire without expecting it to crack, jon, cut some little pieces of exhaust pipe to fit in there. If you use a high heat setting and wire brush the cast iron before you weld, it should hold just fine... mine does

Re: NOBODY IN WI CAN WELD! *rant*
 

;)

Re: NOBODY IN WI CAN WELD! *rant*
 

My O2 housing looks the same way, but my buddy adam managed to weld the piping to the cast. I dunno how stong or how long it'll last, but it passed the hammer test ;)

Re: NOBODY IN WI CAN WELD! *rant*
 

mine did too paul

Re: NOBODY IN WI CAN WELD! *rant*
 

try to fill that gap with a smaller piece of metal, not just filler.

Re: NOBODY IN WI CAN WELD! *rant*
 

;)

Re: NOBODY IN WI CAN WELD! *rant*
 

bring it to my house and I'll put a stealthmode "snakeskin" weld on it. I'll gaurantee it for life. O0

Re: NOBODY IN WI CAN WELD! *rant*
 

Damn I was just up in Minneapolis too. I'm gonna give it a shot with the flux core and pray it works

Re: NOBODY IN WI CAN WELD! *rant*
 

Do this, get a reducer from a parts store so one end is closer to the size of the flange and the other end will fit you DP. Bake the cast iron in the over and then weld it. From what I've read, welding cast doesn't work majority of the time 'cause the heat is disapaited away from the weld. When you done allow it to gradually cool down. I'd think this method would work a million times better than flux-coring the shizz outta it.

Re: NOBODY IN WI CAN WELD! *rant*
 

MMM, I've never welded cast with flux core, But for extra filler, grab a 6013 Stick from an arc weld, hit it with a hammer to chip the slag off and use it like a tig stick with your flux core, The stick will act as an extra filler, taking the heat alittle bit from the mild steel and adding space.

Re: NOBODY IN WI CAN WELD! Completed *pics*
 

pics up top

Re: NOBODY IN WI CAN WELD! Completed *pics*
 

jago thats not bad at all man. good work

Re: Downpipe completed *pics*
 

so just to clarify, you have a wideband O2..but that is the POS you have as a downpipe? :S

Yikes.

Re: Downpipe completed *pics*
 

You got it. I'm not dumb enough to run a turbo setup without a wideband, but I will use any means necessary to get the downpipe to work >:D

Who gives a ---- how it looks, I always preferred ugly cars that go fast and surprise the ---- outta people.

Re: Downpipe completed *pics*
 

sure, but there's a limit i think. You can have a sleeper looking car that goes fast doesn't mean it has to be that hacked up. There's hacked up..then there's this.

but, props to you for trying it and for posting pictures on the internet.

Re: Downpipe completed *pics*
 

itll flow good enough to go fast, thats all we care about. Who the ---- is gonna start looking at his downpipe?

Re: Downpipe completed *pics*
 

looks good to me 8)

Re: Downpipe completed *pics*
 

Looks fine. HMT bitch. I was thinking about getting an external gate and slapping it on my HF manifold where the original O2 goes.

---- should hold fine... Its not like the car will go veer off a cliff if it cracks. Fluxcore kicks ass with the right prep and welding technique. I'm using a Harbor Freight Unit... MIG-100 got it on sale for 80 bucks. Using some Lincoln Electric flux wire and spraying the surface a lil bit with anti-spatter spray...everything comes out clean.

Re: Downpipe completed *pics*
 

jb weld that ----

Re: Downpipe completed *pics*
 

jb weld your penile cavity fool

Re: Downpipe completed *pics*
 

Who is supposed to care how it looks, it does the job so it gets my approval O0

Re: Downpipe completed *pics*
 

what the u just keeped weling till it fill that the emty space

Re: Downpipe completed *pics*
 

looks like you need more heat nigga.

Re: Downpipe completed *pics*
 

tittys. screw how it looks. if it works it works

Re: Downpipe completed *pics*
 

If it ain't ugly it ain't HMT.

Re: Downpipe completed *pics*
 

There ya go.

I made this same post on H-T and got flamed, whoda thunk? :P

Re: Downpipe completed *pics*
 

Oughta ugly up some whitey bends and go skeet on them bitches jago.