Exhaust Fabrication Tutorials

Hi Sean,

Like you I take on most things myself, but not exhaust system welding.  I’ve done a lot of welding and I still would not do it.  Welding exhaust systems is a skill that takes time to develop.  The tubing needs to be purged internally with inert gas while being welded, and of course the welder itself must use a shield gas. If the heat is not just right the heat affected zone (HAZ) will be compromised and will crack quickly once put into use.  If it were me I would concentrate on the design I wanted, then get an experienced aircraft exhaust shop to do the fabrication and welding.  

Hi Jeff,

My intention is to take the precut pipe work to a skilled welder. 

I should have framed my question more precisely - I would like to see a video(s) on how to do the measuring/cutting so as to achieve the required shape to improve the exhaust: frame clearance.

 Coupled with this is having to do the test fitting/measuring in situ.

You are probably better off letting the welder cut and fit the pipes. They can be very particular about the fit up and may charge you more for welding pipes someone else cut.

I know you are quite crafty Sean, but I’ve got to agree with Sam on this.  I think it will cost the same or more if you cut the parts yourself.  

However, if it’s difficult to get the aircraft to an exhaust shop I understand why you want to do it.  It would be tempting to have it all mocked up and just take the one section to a welder.  Maybe if you pick the welding shop first they will coach you through it.   

"Crafty"?????

I will have to do some research into welding services located in/close to airfields at this point I only know of one and it may not be appropriate for what I am trying to achieve - can only ask.