Getting some welds done

Doing an Evo 8/9 stock replacement manifold today. I back purge these with a plate and fitting on one side and aluminum foil on the outlet.

My first manifold turned out pretty good. I would say I was getting 95% penetration with a single pass, very mild work with a die grinder and there was no evidence of a joint on the I did of the tube.

Custom turbo manifold for a cobalt ss

Damn, I honestly never thought about making a dam, I use foil to plug the pipe for back purging but I'll definitely give a dam a shot. Thanks dude.

So I'm trying to get this all welded up and I'm trying to figure out how to get in this tight of an area. I normally run the very large Pyrex cup with a lot of stick out but I think that the gas is being blown away. Am I going to need one of those super small long comes or should I rig up a secondar...

I absolutely mean to do 2 passes. When I said i thought I could get better cover I meant the cover pass. The root was very small and that meant I had to push a lot of wire into the cover pass and it just barely got flush with the bevel. You also hit it on the head that people who claim to get full p...

Root pass and cover pass. I didn't make the gap big enough and I didn't push enough filler wire in to build it up. The root came out pretty good, I think if I would have built up the root a bit more I would have got a better cover but I'll keep practicing.

Thanks for the input guys. I absolutely understand the reasons behind doing 2 passes and for doing a single pass. I guess someone had to say it, only a master welder can get the proper results on a single pass. That's fine with me, it gives me a goal to aim for. I'll be doing some 2 pass joints toni...

This was a single pass, no root. I think I need a slightly bigger gap and to push more filler wire in the joint. It was on the ragged edge of getting good penetration but I didn't wanna push it to hard.

Oh I'm getting close, first bit of weld so the pipe was cool. Beautiful color and full penetration. The weld is flush with the pipe. Amps set at 160 bit obviously not using that much. .035 filler wire with a tight .035 gap. I think setting up an aluminum heat sink will really help keep the heat down...

Same amps for the 3/32 filler, I'm gonna try again with the .035 filler feeding it faster. I knife edged the joint, left about a .035 gap, wire wheeled it, cleaned with acetone, back purged the pipe and verified 18cfh out of the huge Pyrex cup.

So towards the end of the weld I started getting the results I wanted. Good penetration, good color and stacked dimes look. I did notice that if I tried running 3/32 filler rod I had to get to hot and it turned gray. With about 100-110 amps and .035 filler I got decent results. Just gotta keep pract...

Got home today so I'll try those settings tonight after work

Won't be around this weekend but next week I'll be trying several different techniques to get the results I need.

Yes, those are Googled images just to show my end goal. From what the guys That produced these types of welds are saying, it's sch 40, single pass with 100% penetration. Honestly I'm more concerned about getting 100% penetration and a good flush weld. The reasoning behind the coloring from what I un...

This is what I'm aiming for.....

Switched to bigger filler wire to try getting a flush weld with the pipe. Still not getting 100% penetration and I had to run it to hot to get full fusion of the bigger wire and the pipe. This project is really kicking my ass.

Same settings but tried going faster to get better color.

First weld, pulsing at 95amps with .035 filler wire. Looked pretty good just concave. Knife edged bevel with no gap.

Max amp was set at 130 (I believe I'm using about 90-110 amps on the pedal), I was using 1.2pps, I'll admit I didn't do the best job keeping the torch at 90* on the pipe.

So I tried a shaper bevel and it worked out pretty good, still not getting 100% penetration but it was a gapless joint. Im going to try the next one with a .035 gap since that is the size of my filler wire.

Yes, I actually had a problem not venting the end of the pipe and it would blow the weld out.

I have noticed that I move a bit slower on stainless so I have been playing with the pulsing so I can work slower and keep the heat low to get the good coloring that I want and good penetration.

Awesome, thank you, I'll definitely keep practicing at it. I'm trying to build these manifolds for a business.