Welding Tips and Tricks

Hi All,

Looking for some help...
When welding a header (or exhaust manifold) out of Sch10 1 1/4” pipe, should you be butting the two pieces up or leaving a gap? Based on this, should you be looking for full penetration or is that not necessary? I have watched a lot of videos on welding manifolds but none actually show it there is penetration or not and it’s usually done butted up and in one pass.
When I have practiced I can’t get full penetration when it’s butted together.

Look forward to some tips, let me know if more info is required

You want to back purge the joint, butted. This will almost guarantee a perfect interior joint and eliminate oxidation internally.

Do you bevel to a feather edge or use a land? As long as the weld is sound CJP isn't necessary, but as CJ wrote you do need to back purge.

LtBadd wrote:Do you bevel to a feather edge or use a land? As long as the weld is sound CJP isn't necessary, but as CJ wrote you do need to back purge.

CJP?

Noobie here needs the definition

I personally would bevel 30 degrees to knife edge and gap so 3/32" wire won't fall through. Then lay wire method and walk over the wire fast 70-75 amps so as not to over penetrate or open up a keyhole. Purge is a must.
You may need to cap with 1/16" wire about 65 amps. Once you get the hang of it you can do it in one pass by pushing more wire into the weld pool.

I have been using the bevel that has been provided on the welding els. Rather than jump into a manifold I decided to get some practice in first. If I was to have to make cuts (which I will) my intention would be to recreate the same bevel.
In terms of purging, that is my intention. Question is, gap or no gap? Also filler or no filler for root?
Cheers for the help so far

Radishfever wrote:

LtBadd wrote:Do you bevel to a feather edge or use a land? As long as the weld is sound CJP isn't necessary, but as CJ wrote you do need to back purge.

CJP?

Noobie here needs the definition

complete joint penetration

Purge. No gap. Quality fit.
I like pulse for this application personally.
Sched10 is pretty thick for a header pipe. What is the motor?

It’s for a TD5, weight isn’t an issue so I am happy to go safe rather than be sorry