Welding a muffler tailpipe

[Nandy]

So I took a curve a bit too fast, got in the ditch, did a "duke of hazzards", when my tires hit the pavement again I did a 180 and end up in the other side of the road in the embankment of the creek. One tire came off the rim a bit and that was what made me do the 180. Anyway, the tally of damage...

The tire that came off the rim (probably all it needs is to be inflated again)
Muffler tailpipe got stuck in the dirt and got bent. No apparent damage to the silencer or any other part.
So, I can just cut the tailpipe for now but I want to get it replaced. I have oxyacetilene but I have never replaced a tailpipe. I got priced 48.00 for the tailpipe. Called one of the muffler places in here and the guy was already leaving but he say it should be around 40. If he is correct then I would not do it. But the other place said 130.00. In that case I am doing it myself as I am short in funds..

Anyway, any tips for a diy guy will be helpful.

 

[Bob_VT]

Re: Welding a muffler tailpipe

Depends..... I have welded them in my ghetto days with a oxy/acet torch and a wire hanger (long time ago) when the tail pipes "were" just steel. Now many have stainless in them and are weird metals.

If it's just a tailpipe after everything in the system..... get a stainless muffler band clamp and that will work on a butt type attachment w/o welding

 

[Bart Sr.]

Re: Welding a muffler tailpipe

Where is the bend?
Is the bend a curve or a kink?
If curved I can't help.
If kinked I would cut out the kink and get a reducer section with two muffler clamps and connect together.Might cost +/-$12.
OR
If kinked cut out the kink,get two hose clamps and two soup cans.Cut the ends out.Slice lengthwise and place over the ends with the openings on opposite sides and clamp the ends.

 

[Nandy]

Re: Welding a muffler tailpipe

It got bent to almost 180 degrees as the momentum push the blazer in the embankment. Those are good ideas. Thanks! Any other ideas will be welcome.

 

[SuzukiChopper]

Re: Welding a muffler tailpipe

If you don't care about the cosmetics of it too much until you can afford to replace it... heat it up and start bending it back. Get it to the point you can get a piece of 1/2" round bar inside... keep heating and push out the kink with the round bar from the inside. With enough finesse you should be able to get it close to its original shape. If its close to the gas tank though, don't do it.

Other option is cut before the kink and go to an autozone or something similar and buy the pipes and clamps you need to replace it... probably $20 at most.

 

[Nandy]

Re: Welding a muffler tailpipe

Thanks guys!

 

[mthieme]

Re: Welding a muffler tailpipe

How far back from the end is the bend?
Sounds like $40 on a new tailpipe would be the way to go.
It's gonna tough to get the kink out.

 

[lowkee]

Re: Welding a muffler tailpipe

I vote to forego the repair shop and go Bart's route with the reducer and two clamps. On our way to DC one night, my wife hit a retread on the highway and ripped the muffler off (we lived in Maine at the time). Long story short, we pulled off the highways, hit up an autozone for exactly the same reducer and two clamps and were back on the road within 15 minutes. That lasted me just perfectly up until I needed an inspection (they will fail non-welded fixes). Would have lasted the life of the pipe, IMO.. picky state.

Instead of getting it welded at a shop, I'd recommend just buying a welder for nearly the same price. A cheap mig welder at harbor freight costs $90 and comes with enough wire to weld the next 50 pipes you rip off going 'a bit too fast'.

 

[Nandy]

Re: Welding a muffler tailpipe

Sorry guys for the delay in updates... I got the reducers and 2 clamps. The muffler was too damaged to fix so I just cut the end and close to the silencer and put it together there. The silencer is leaking at the bottom thru a very small crack so there is a silencer in my future. When I get there I will then replace both the silencer and the tail pipe.
I have oxyacetylene and a stick welder. Do you think I can use the stick welder? I rather use that than the gas welder but would be a bit worried about the possibility (either in my imagination or real) that somehow it could fry my vehicle computer... Any ideas?

 

[lowkee]

Re: Welding a muffler tailpipe

Stick welder will work just fine. I'd highly recommend removing it from the vehicle before welding it, as you won't have much room under there with a 12" stick protruding from your hand. You can patch up your silencer the same way. Save yourself some decent cash by doing it yourself. Always gives you a warm fuzzy feeling knowing you did it youself, as well.

 

[Bob_VT]

Re: Welding a muffler tailpipe

Sorry guys for the delay in updates... I got the reducers and 2 clamps. The muffler was too damaged to fix so I just cut the end and close to the silencer and put it together there. The silencer is leaking at the bottom thru a very small crack so there is a silencer in my future. When I get there I will then replace both the silencer and the tail pipe.
I have oxyacetylene and a stick welder. Do you think I can use the stick welder? I rather use that than the gas welder but would be a bit worried about the possibility (either in my imagination or real) that somehow it could fry my vehicle computer... Any ideas?

Disconnect the battery completely both + and - to be safe with your stick welder.

Be real careful of the fuel tank and fuel lines ........ (been there done that and even got the fire out! )

 

[j_martin]

Re: Welding a muffler tailpipe

I've found that when welding thin stuff like this, a small diameter 7014 rod works well. It's a low penetration, fast deposit rod so it makes a pretty weld with ease. In the old days, we always gas welded them.

john

 

[SuzukiChopper]

Re: Welding a muffler tailpipe

I've seen muffler shops stick, mig an OA weld mufflers/pipes/resonator/etc so all will be fine. Each time they do it on the car itself with no problems, just watch what you're doing and plan your weld ahead of time.

 

[BlazinKuztumz]

Re: Welding a muffler tailpipe

Reducer, clamps and new section of pipe would be your best, easiest (non-welding) method of replacement/repair. If you have a rose bud tip for your torch and some rod, you could try the straightening method as well, but not sure you'd get very far, depending on the amount of damage done to the pipe when it was bent. You could find out that you end up with it cracking where it was bent, even with heat being applied. The welding, you can use tig/mig/stick/oxy, and all will work great. If it's a mild steel pipe, you are fine with most regular wires/rods, but if it's something special like stainless or aluminum, you'll have to set up with the right equipment to do it. Whenever welding on your vehicle with a tig/mig/stick welder, always disconnect your battery to protect it and the electrical system within the vehicle. Also remember to ground as close as possible to your welding location, for better penetration, and reduced electrical flow through the vehicle. With the oxy torch, you don't need to disconnect it, but watch your open flame placement, as well as your direction of sparks flying. Could be an explosive experience otherwise. LOL

 

[Nandy]

Re: Welding a muffler tailpipe

I will probably end up using my stick welder. Will probably tack weld in place then take the part out and finish it up as I have to weld around it and there is no space in that suv. Blazing, I have to weld it before inspection as in this state you would not pass inspection unless the muffler is weld. Inspection is not due until Sept.