I know it'll be a pain in the butt, but no supporting vendors are in town, and I don't know who to trust to do the install. Don't want to take my car to a muffler shop for this. I had though about bolting the headers on and cutting the pipe before the cats myself, and then getting it welded somewhere, but am now thinking maybe I can do the whole job myself.

I had a welding class in high school (Got an A in it, too :D), so I have a little experience with MIG, TIG, oxy-acetalene, etc. Wire feed was easy compared to the others. Are these little $150-$300 wire feed welders at Sears and other places any good? Can I use a welder with flux core wire, or do I need seperate inert gas? Can anyone recommend a specific model? Is a 110VAC welder sufficient, or are they crap compared to the 220VAC models?

I can practice welding on the piece of pipe I cut off in front of the cats (to choose the wire diameter and set the voltage and feed speed), so I'm not too worried about the quality of the job, assuming I have decent equipment.

I'm getting the RK Sport headers from Andy at A&A, so I'll ask him for installation instructions. Anyone have any install tips aside from that?

Thanks,
Miles


[Modified by Miles in Michigan, 3:59 PM 6/18/2002]

 

I have a Lincoln SP 125 welder that runs off 110VAC this machine is Awsome for anything you will ever do to an automobile. I did in the past have one of those small machines your talking about, that use flux core wire. this type of machine is ok but makes a very dirty weld, lots of splatter. I was not happy with the quality of welds that machine offered.


[Modified by Sixguns, 8:13 PM 6/18/2002]

 

Mine is just a 110. Don't use flux core , though. It's really bad.

 

Cool, thanks for the reply. I found a Lincoln SP-135T for $420, including shipping. It is the "T" model, which I think has several discrete settings for the amperage, versus the "+" model, which has a continuous adjustment (but costs $570).

Is the "plus" model worth the extra $150?
<edited to include lowest prices I found>


[Modified by Miles in Michigan, 8:44 PM 6/18/2002]

 

What make and model is yours?

Thanks.

 

I have installed two sets of Melrose LT headers in C5's. These go in with minimum hassel and work great. To finish the job you need the following items:
One 3" 'U' bend.
Four 3" header flanges
Any decent 110 MIG welder w/mixed gas (use nothing larger than .022 MIG wire).
Skill saw w/ abrasive cut-off disk (Home Depot)
One coat hanger
1) Put the car on a lift or jack stands.
2) Remove the 'H' pipe.
3) Cut off the head pipes right at the front of the cat.
4) Re-install the 'H' pipe.
5) Cut and bend the coat hanger to simulate the bend radius and length of the short section of pipe needed between the collector and the cat.
6) Use this to locate a section of your 'U' bend, mark it and cut out the section.
7) Trial fit the piece and trim to fit with about 1/4" (total) clearance while held in place.
8) Weld three 3/8 UNC nuts to the back of one of the header flanges.
9) Position this flange on the collector and rotate until you think you can get a wrench on all three bolts during assembly. Leave about 1/2 of the thickness of the flange sticking out from the collector.
10) Weld the flange to the collector from the aft side on the inside diameter. Keep the weld bead small.
11) Bolt another header flange and gasket to the one you just welded on the collector.
12) Position the short section of 3" pipe in place inside the bolted header flange and the cat.
13) Tack weld the pipe to the flange and the cat.
14) Repeat this process on the other side.
15) Remove the 'H' pipe with the tack welded flanges and pipes.
16) Seal weld the pipe to the cat and to the header flange all around on both sides.
17) Re-install the 'H' pipe, cat back mufflers etc.
18) Drop the car back to the ground.
19) Enjoy your new found power with pride and satisfaction of doing it yourself...
If you have any questions, get back to me by email.
Shirl :D


[Modified by MrEracer, 3:10 AM 6/19/2002]