I have been tryng to weld a dsm BOV flange to a 2.25" exhaust pipe. I am using a arc welder and it is a f_&*(ng pain in the ***. The flange (cut out of the original piping) is a softer metal than the exhaust and takes alot of effort not to melt it even with the voltage turned down. I have tried everyting.....thin rods-low temp.......thcker rods-high temp.......grinding then layering..... I can't seem to get a air tight seal. I'm sure it is partially b/c I am a boob at welding but I have a feeling using a different style welder might make it easier. So after my rant I have two questions.
1. What can I do to get this to work with what I have? (Pepboys exhaust pipe,flange cut off of DSM Piping, and Arc welder)
2. I saw someone who used JB weld to hold the two together will this work w/o my BOV shooting off one day? (8-10psi of boost)

 

are u sure your not trying to weld aluminium to steel :1 Just JB Weld it

 

The DSM BOV flange is steel fo sho. It is a bit softer thought. I thought of JB welding it but is JB weld going to hold at 8-10 lbs of boost without weakening?

 

no you can't jb weld it. m ake sure you grind it clean