Custom exhaust fab question. (expeienced fabricators please read)

[90T04]

I have made lots of custom exhaust systems, hardpipes etc, and I am just wondering what you guys are using to cut the mandrel bends perfectly strait, yet at the required angles, to make a butt weld. I know there has got to be an easier way than how I do it. I have been using a marker to draw the line I need and then a cut off wheel on a grinder to cut it. I have thought about using a chop saw, but how are you going to clamp the pipe in there for the cut? I seems like chop saws are usually made for straight pieces of stock that can be clamped in the little vise.

I can get the cuts okay with a cut off wheel, but you always end up with gaps that you have to fill, big ugly welds, and then you get the poke throughs from the MIG wire, etc, etc,

A guy once told me you can get a piece of copper or brass sheet and make a little ring out of it and put it inside the pipe under the seam while you weld, and remove it when you are done, which seems like it would work, but the seam isnt always accessible when you are working with bends and long runs of pipe.

Anyway, just wondering how the pros are doing it.

Thanks
Ryan

 

[dbsupra90]

well im by no means a pro, but it aint my first rodeo either.

we've always used a chop saw. the one i have the clamper is adjustable in width and angle. if its a tight angle you have to sometimes do one side then flip it over to do the other. if its a super tight angle you use a band saw. those are a little spendy tho, but real handy. if you dont have access to that the real tight stuff you'll have to do by hand. 95% of the stuff we've used a chop saw no problem.

another option is use a chop saw and section up the bends. thats time consuming and not crazy about how the multi sections look. but that works too.

here is a pic of a set of pipes we did on chris's car using nothing but a chop saw.

 

[Slow66]

if its a super tight angle you use a band saw.

^^^

The best way is with a band saw...bar none.

But since theyre so expensive, its not in the budget of most of us.....(ive been trying to save for one for a while now)

As long as the clamp on your bandsaw pivots, you can make due sometimes by usign angle cuts of wood to wedge between the guide and the object your cutting and clamp against it. You will still need to hold the piece whilst cutting, especially on the bigger diameter pieces. Even if you can just start the angle with the chopsaw, and finish it with the angle grinder, youll still save some time.

Thats abotu all i got

 

[Facime]

well if ya end up with big ugly welds you can throw a flap disk on your grinder and grind em smooth. That at least helps with the appearence. I dont have a chop saw or a band saw (...yet, I will have one in TX though) so I do what you do and that is use a cut off wheel. I have gotten to be pretty good with the cut off wheel and can cut nice straight lines. Again if I need a little help, a flap disk can clean up my cuts a little.

Yeah, if I had my choice I would be using a band saw.

 

[KevinM]

Yep, on my first exhaust and IC piping setup, I used a bandsaw.

Now I have a chopsaw where I'm at and make that work. I usually just hold it myself which isn't the best, but I haven't made any big mistakes yet, and it doesn't take long to re-cut or replace if needed.

 

[jetjock]

While upright band saws aren't cheap you can get the tilting ones for cheap at Harbor Fright, Grizzly, Enco, etc. Chinese yes, but as long as you don't abuse them they'll last. Great for cutting solid stock too. Here's examples from Grizzly:

http://tinyurl.com/35dwbg

I have both one of these and a chop saw. Either does a good job.

 

[suprarich]

Yep, self feed band saw here too. Works great. Then I clean up the cut with a vertical fixed position belt sander.

 

[cjsupra90]

I use a regular stand up Bandsaw but I have several jigs (wooden blocks with verious commenly used pipe sizes and radius's cut in to them to hold the pipe correctly) that I can attach to a aluminum plate the is guided by the table and allows me to get the angle that I want and ensures an exact and straigh cut

 

[90T04]

Awesome, thanks for the tips guys, I think ill end up finding a used band saw somewhere for cheap.

 

[suicide]

i use a reciprocating saw for all my work and i grind my welds down to make it look better....

here is a pic after welded then grinded down, after this i will be painting or powder coating it... it will look perfect once completed,

and for IC piping i pressure the pipe to check for pin holes and go back re weld ad do on....

 

[MK3Brent]

I use a chop saw personally.

Nice and straight, perfect for welding pipe.

 

[jt2ma71]

I use a chop saw personally.

Nice and straight, perfect for welding pipe and tubing.

same here

~Ron

 

[Mr.PFloyd]

same here

~Ron

x3 for me.

 

[MDCmotorsports]

I have a chop saw here also, with a chuck/jaw setup that has adjustable angles.

If I had my choice though, it would be a band saw or cold saw with fluid.

 

[gixxer750]

the dewalt low speed bandsaw type thing is FTW. You can cut solid aluminum stock with it, pick it up immediatly without burning your hand, and it leaves very few burrs. It cuts steel just as well.


But yeah, I use a chop saw.

And I DON'T grind my welds down I've got far two many hours into making them look pretty to grind off

 

[90T04]

And I DON'T grind my welds down I've got far two many hours into making them look pretty to grind off

Im with you there, nothing like a good looking bead on your custom parts.

I use a regular stand up Bandsaw but I have several jigs (wooden blocks with verious commenly used pipe sizes and radius's cut in to them to hold the pipe correctly) that I can attach to a aluminum plate the is guided by the table and allows me to get the angle that I want and ensures an exact and straigh cut

cjsupra90, that jig system sounds interesting, Id like to see some pics or something of how youre doing that.

 

[Facime]

lol, yeah, I grind mine off.....cause they suck! Still learning. I can tack weld like a maniac though :biglaugh:

 

[johnathan1]

Use one of these:

Works great every time.

 

[MK3Brent]

Band saws are really the best way to do it IMO.
My chop saw likes to take alot of material out when it cuts.
Chop saws will also leave a LOT to clean up after.

Here are some example cuts I have made with one after cleaning:

You can even cut perfect angles too, like some mentioned.

 

[s383mmber1]

Use one of these:

Works great every time.

:rofl:


And Brent, those look great!