Finished up another manifold the other day...well almost. :) (Lot's o pics!)

[Race Egr]

Damn 120 amps im using around 75

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[B18C1CYA]

Well you have the right method , set it high and learn heat control I have mine set around 135 amps or so , I never touch the setting on the welder for any thing realy , also rebeveling is a must on sch40 to get 100% , you can on sch10 without rebeveling , I have benn messing around with diffrent sch's for the past few weeks and was almost going to make the change , but I would just stay with sch 40 for the added strength also PM me any time if you have any ??? 's Bryson

[Race Egr]

So b181cya you only do one pass correct? Thats all I did when I was welding sch10 and it filled the bevel perfect. I was usin 1/16th filler I dont weld sch10/40 much and its a pita to work with

[B18C1CYA]

Originally Posted by dr.NAPIER

So b181cya you only do one pass correct? Thats all I did when I was welding sch10 and it filled the bevel perfect. I was usin 1/16th filler I dont weld sch10/40 much and its a pita to work with

yes singal pass I also found with sch10 there is alot of stress on the tubes when you cut them , and when you weld them they shrink up alot more than sch40 ,

[CSaddict]

I root pass and cap pass all my schedule 10 piping. Heavy bevel with a 90 amp root pass, with an 85 amp fill pass. Seems to work well for me. I am just a hobby welder. I make mostly manifolds when I have free time. Bryson, I am the guy from the Jeep site that remembered you from EF-honda.com Your work is very much improved since I last saw your work.

[RCautoworks]

Originally Posted by Boostwerks.com

Why not? I think if you can completely fill the bevel with the puddle and not have the weld be concave, there is nothing wrong with doing one pass.

Are you gapping the pipe at all, I still don't see how some of you guys are doing one pass. I have never ever gotten away with one pass, I just don't see it happening either.

I also have received advice in the past and talked to engloid, and searched and read everything the guy says. A few things he says

". Many people think that full penetration means that you have to weld the entire thickness in one pass, and this is seldom the case. If I weld 1/4" material and want full penetration with tig, it will likely be done in 3-4 passes. "

"And, although it's commonly thought of otherwise, you don't have to weld the entire thickness in one pass. In fact, in every industrial welding job I've ever had, they'd be rather upset if we welded it in one pass. Military weld specs require 2 passes, at least. On sch10 pipe, I'd probably make 2 passes. One would just be focused on getting the inside root pass to look nice. The other would fill the bevel and put a nice final pass on the outside.

Notice in the weld below, this is the "root pass." There was no effort made to fill the bevel, only to put a nice bead on the inside. (this is carbon steel)"

I don't doubt anything this guy says, he knows his stuff.

[cua0]

no, he was a good asset around here.

shame he was banned over some stupid shit in the bike forum

[RCautoworks]

Originally Posted by cua0

no, he was a good asset around here.

shame he was banned over some stupid shit in the bike forum

No doubt, I'm still in contact with him.

[RC000E]

Originally Posted by 90blackcrx

Are you gapping the pipe at all, I still don't see how some of you guys are doing one pass. I have never ever gotten away with one pass, I just don't see it happening either.

Bro, I'm with you 100%, I have NEVER single passed any of these. Hotrex use to preach about his one pass wonders and his manifolds damn near fell apart on their own in the early days.

Bryson, do yourself a favor man....bevel, do a root pass, and work on your consistency. I think you'll find that if you do a root, then a fill, your welds will look a hell of alot better, and penetration is guaranteed. On runners, I can't recall ever even using beyond 90 amps much less 125....and even at 90 I am backing off.

[*Boostwerks*]

Originally Posted by RC000E

Bro, I'm with you 100%, I have NEVER single passed any of these. Hotrex use to preach about his one pass wonders and his manifolds damn near fell apart on their own in the early days.

Bryson, do yourself a favor man....bevel, do a root pass, and work on your consistency. I think you'll find that if you do a root, then a fill, your welds will look a hell of alot better, and penetration is guaranteed. On runners, I can't recall ever even using beyond 90 amps much less 125....and even at 90 I am backing off.

I just want to make it clear that i never said I wasn't beveling the pipes. I match straight pipe or any cut pipe to that of the pre-beveled surfaces. Theres no way I would weld up pipe this thick that hasn't been beveled. I'd also like to make it clear that I've never had a single cracking issue, personally or with any of my customers.

Yeah I'll definetly try doing a root pass, and then filler pass and see how it turns out, but I've been taking RLD's advice ever since i started TIG welding, and have had great success.

[B18C1CYA]

The secret to singal pass is heat control , it took me over a year to figure it out , just do search's and you will see from many how it is done , some people to learn from , Tinker219 and the full race team , there are lots of pics around of there stuff that you can study from , If I get time 2 marrow I will get some pics for you guys of step by step prep and the end result also no need to double pass sch10 you should kill that in a single pass and be at 120% penn ,

[RCautoworks]

Originally Posted by Boostwerks.com

I'd also like to make it clear that I've never had a single cracking issue, personally or with any of my customers.

That's good, but there is always room for improvement you know, I mean sch10 and 40 is plenty strong that a monkey could weld a top mount and it probably would not crack, that does not mean it was done right.

Originally Posted by B18C1CYA

The secret to singal pass is heat control

I'm not doubting or arguing with you but I still can't see it being done, I would imagine you would have to sit in the same spot for awhile, and push the rod in enough times to get the weld to where it needs, sitting on one spot with that much heat can't be ideal. Have any links to read what you are stating ?

[RC000E]

Originally Posted by Boostwerks.com

I just want to make it clear that i never said I wasn't beveling the pipes. I match straight pipe or any cut pipe to that of the pre-beveled surfaces. Theres no way I would weld up pipe this thick that hasn't been beveled. I'd also like to make it clear that I've never had a single cracking issue, personally or with any of my customers.

Yeah I'll definetly try doing a root pass, and then filler pass and see how it turns out, but I've been taking RLD's advice ever since i started TIG welding, and have had great success.

To further clarify to readers, I in no way meant to imply your manifolds would fall apart. I was merely citing that other "one pass" guys had manifolds that did, despite their claims to getting big penetration.

[*Boostwerks*]

Originally Posted by B18C1CYA

The secret to singal pass is heat control , it took me over a year to figure it out , just do search's and you will see from many how it is done , some people to learn from , Tinker219 and the full race team , there are lots of pics around of there stuff that you can study from , If I get time 2 marrow I will get some pics for you guys of step by step prep and the end result also no need to double pass sch10 you should kill that in a single pass and be at 120% penn ,

Thats exactly what I thought. It's hard for me to beleive that when welding in the bevel, that the metal underneith the puddle isn't getting formed into the bead. If the heat is hot enough, but not overly hot to burn it, the base metal will easliy form with the puddle. Thats at least how I've seen it.

That would be great man! I was thinking about welding up a pipe several different ways, and then using a crush method to see how well the seam holds up. It would definetly be interesting for me to see.

Originally Posted by 90blackcrx

That's good, but there is always room for improvement you know, I mean sch10 and 40 is plenty strong that a monkey could weld a top mount and it probably would not crack, that does not mean it was done right.

Of course! I'm not trying to imply that your wrong or anything. It's just that several other's have done single passes with great results. although If it works, then it's kinda hard to argue whether or not it was done right or not.

Originally Posted by RC000E

To further clarify to readers, I in no way meant to imply your manifolds would fall apart. I was merely citing that other "one pass" guys had manifolds that did, despite their claims to getting big penetration.

Hehe. . we just don't want the thread getting into a "pacesetter makes ferrari exhaust" thread again...lol.

[B18C1CYA]

Here is a link to Tinker219 (Cody) aka love fab , http://www.honda-tech.com/zerothread?id=1103067 you can learn alot from this post , you just need to work at it

Here is one about Full-race http://www.honda-tech.com/zerothread?id=898516

Figure if you want to be the best , Y not try to learn from the best , these 2 threads help out alot

[RC000E]

Originally Posted by Boostwerks.com

Hehe. . we just don't want the thread getting into a "pacesetter makes ferrari exhaust" thread again...lol.

No doubt...hahaha...we schooled those rednecks

[anusol]

2 passes for me thanks. looks better, but theres still a ways to go

do yourself a favor and never write on the flange with the torch again. thats hotrex territory.

[RC000E]

Originally Posted by B18C1CYA

Here is a link to Tinker219 (Cody) aka love fab , http://www.honda-tech.com/zerothread?id=1103067

Checked this thread out....200+ amps for single pass penetration. Welds look a little funky though like they are too hot in places, which is how most buyers judge the product [looks]. A balance of strength and "prettiness" is what people like to buy in my opinion.

[RCautoworks]

Originally Posted by RC000E

Checked this thread out....200+ amps for single pass penetration. Welds look a little funky though like they are too hot in places, which is how most buyers judge the product [looks]. A balance of strength and "prettiness" is what people like to buy in my opinion.

Also thought the welds looked rough.

[*Boostwerks*]

Originally Posted by RC000E

Checked this thread out....200+ amps for single pass penetration. Welds look a little funky though like they are too hot in places, which is how most buyers judge the product [looks]. A balance of strength and "prettiness" is what people like to buy in my opinion.

Yeah, I'm pretty sure he doesn't use that method anymore. I know he's using mainly the walking the cup technique, but I don't know if he still does that with one pass.

[Throwdown]

nice mani ..

[9bells]

Stainless in particular is more prone to stress build-up from multiple passes.
The thermal conductivity presents it's own problems, as does carbide precipitation.
Higher welding current and fast travel is key to letting the weld metal cool sooner.
Too much heat with slow passes increases grain growth near the weld, decreasing
strength and ductility.
If two passes are used, the first should be relatively hot, and fast, while the second
should be the same.
It was mentioned earlier that this is how a few gus were doing it.

I think 2 generally looks better on the heavier stuff, but some guys get carried away with the cap.
Nice manifolds though. This section is full of talented guys.

[CoreyR]

nice work bryson, much better than your older stuff. but seriously 2 passes (root/cap) especially on a topmount.

[B18C1CYA]

Ok guys here is some pics ,

Here is sch40 b4 you bevel it



after you bevel



tacked up



weld started



weld completed



pennatration side , just to note I did not have enoff gas to backpurge this weld but if I had backpurged it would have turned out alot nicer on the inside.



Here is a pic of my torch to show I dont use any thing to fancy , gas lense 1/16" tungsten, 1/16" 308 filler and about 28 argon flow

[B18C1CYA]

also another thing to think about , is it is true about when you over heat the steel , and also if you can do a single pass and get great looking welds with 100% pennatration you save time , wich we all know time ='s money