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Thread: welding rusty exhaust pipe on the car

  1. #1
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    welding rusty exhaust pipe on the car

    i was working on a family friends car, and the exhaust was cracked clean off after the y pipe. the exhaust system is old and rusty, and has been willy'd back together a handful of times before i got my hands on it. with the pipe being still there i cleaned it up as best i could and re welded the exhaust about 90% around. now i literally could not reach the top. it was only an inch or two from the floor pan and there is no way to even see what i was doing. anyone try mirrors? what do you guys do in a situation like this? what would a muffler shop do? i would imagine this car was taken to a muffler shop and i can say i could pick my nose and lay my boogers on a joint better then some of these welds LOL.

  2. #2
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    Re: welding rusty exhaust pipe on the car

    You'd be best to replace the pipe. Any exhaust pipe that is old and thin enough to crack will only offer a short lived repair.
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  3. #3
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    Re: welding rusty exhaust pipe on the car

    not really worth replacing the pipe on a car worth $1000. the pipe from the dealer? forget it. fab up my own, waste a bunch of time, and after breaking bolts off, drilling studs out? forget that too. the repair will last the rest of the life of the vehicle. was more interested in how to weld all the way around, rusty or not.

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    Re: welding rusty exhaust pipe on the car

    Normally you can tack the exhaust and then drop the hangers until you have enough room to get the top side. Being at the Y you'll need to tack it and then drop the Y until you can get it. I'd try a mirror before I went to that trouble. Like Slob said... the repair will likely be short lived.

    My son came home the other day and the car sounded horrible. It cracked at the second muffler, right at the hanger, likely what prevented it falling off. I welded it knowing full well it may not last... but he's leaving for collage soon. If it breaks again... I'll order the parts and replace the whole thing.

    Isn't the correct way to "fix" this problem to wrap it with an old tin can and hose clamps? I did that once on the side of the road and the repair held for a couple years.

  5. #5
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    Re: welding rusty exhaust pipe on the car

    Hose clamps... hell no twitch some fencing wire around it!

  6. #6
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    Re: welding rusty exhaust pipe on the car

    When I do a butchered up muffler/tailpipe repair I just continue the weld by sound and feel (use the force Luke).

    Hell, it's only 1/2" or so of blind welding from each direction, and it's not a roll cage.

    Funny how none of my "blind" welds end up with me taking pics of the welds and posting them
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  7. #7
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    Re: welding rusty exhaust pipe on the car

    Quote Originally Posted by forhire View Post

    Isn't the correct way to "fix" this problem to wrap it with an old tin can and hose clamps? I did that once on the side of the road and the repair held for a couple years.
    An, the very definition of a "temporary" repair
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  8. #8
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    Re: welding rusty exhaust pipe on the car

    Sorry guy's and to the original poster; I'm not accustomed to making 1/2 azzed repairs of any type. Simply don't need that type of work, nor the reputation that follows inviting more of the same.
    Slob

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  9. #9
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    Re: welding rusty exhaust pipe on the car

    Thank the Lord for hose clamps and coat hangers!

  10. #10
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    Re: welding rusty exhaust pipe on the car

    Leaks=carbon monoxide =take your chances
    (big gobs RTV (red high temp) tin can and clamps to finish up temp repair)
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  11. #11
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    Re: welding rusty exhaust pipe on the car

    Cut out a little "window" from the bottom, weld up the top part through the inside, then weld the window back on....like so.....








    Ta-Da!




    Man, those were some rough welds of mine from 3 years ago. Back from my Eastwood TIG200 days.
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  12. #12
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    Re: welding rusty exhaust pipe on the car

    thats a good" thinking out of the box" idea...but on real rusty exhaust pipe that could be a big challenge......
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  13. #13
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    Re: welding rusty exhaust pipe on the car

    Quote Originally Posted by Oscar View Post
    Cut out a little "window" from the bottom, weld up the top part through the inside, then weld the window back on....like so.....
    Ta-Da!

    Man, those were some rough welds of mine from 3 years ago. Back from my Eastwood TIG200 days.
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  14. #14
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    Re: welding rusty exhaust pipe on the car

    worked as a muffler man before, I assume your using oxy acet ? if so slide a piece of sheet metal between the floor and your weld bend the filler rod so it will reach on top of the tube just glob it up and then melt a hole on the bottom of the pipe and stick the lit torch in the hole
    and watch for fire on the top where you just welded if you see fire coming through you still have a hole..glob it up till there is no fire coming out the top weld
    its not space science its just an exhaust pipe



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  15. #15
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    Re: welding rusty exhaust pipe on the car

    wow the window idea is kick ***. thanks. i would drop the hangers if it was just a muffler but it was the y pipe. i dont like doing half as repairs either. i do what im paid to do, or in this case not even paid.... lol

  16. #16
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    Re: welding rusty exhaust pipe on the car

    I like the window idea....I was wondering what kind of car it is. If it is a cheap car, cut the window in the floorboard.
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  17. #17
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    Re: welding rusty exhaust pipe on the car

    That window trick isn't going to work so well on a pipe that is real rusty, it will be too thin.

  18. #18
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    Re: welding rusty exhaust pipe on the car

    A complete window doesn't need to be cut out, just three cuts and bend the piece back on the 4th side so you only have three sides to weld up.

    I use mirrors quite often for this stuff and like mentioned sometimes just go by feel and sound. But most always like mentioned, tack it up, and drop it off the hangers till you can see.

    Also like mentioned if it is rusty and thin it will just break again in short time right next to the weld.
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  19. #19
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    welding rusty exhaust pipe on the car

    My old Toyota pickup burned through two Y pipes in the 158,000 I owned it. Each time I took it to the local muffler shop and they unbolted it from the manifold and catalytic converter and replaced it. By the time that sheet metal burns through, there really is no salvaging it IMHO. I don't recall what it costs to fix but it was reasonable. Your neighbors might at least get a quote from someone. They might even be able to find this pipe at a wreck-out somewhere and save some money.

    Just some thoughts.

  20. #20
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    Re: welding rusty exhaust pipe on the car

    the repair is done, i was able to seal the top blind, i wasnt even asked to repair the exhaust. instead i was fixing the cooling system. i just did the exhaust because i noticed it was broken. they would just drive with it broken and not care lol.

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