I did a better job of documenting and photographing the process this last time. Note this process is specific to joining dissimilar metals being a steel pipe elbow to a cast manifold and would not apply to anyone using a cast outlet. 3/32” diameter UTP FN 85 rod works well in this application.



1. Too much preheat is as bad or worse than not enough. 30 seconds with the torch or about 200 F should be enough just to get the molecules moving.

http://rides.webshots.com/photo/2865946850023244788NrGHty

2. Welds should be no longer than ¾” before switching to a blunt pointed air hammer with the air regulated to 50psi max. Peen right away while the weld is hot to flatten it. Peen the entire weld as well as the parent material at the edge of it. Run beads alternately on each side to minimize warpage.

http://rides.webshots.com/photo/2623056950023244788qKReGg

3. When welding is complete get it in the asbestos blanket, sand, kitty litter or whatever you have quickly to slow the cooling. Avoid any cosmetic work as the exhaust from the die grinder or any other breeze will contribute to brittleness.

http://rides.webshots.com/photo/2103491100023244788ExKJjo

4. Some movement will be present so a reface should be planned on to insure trouble free sealing as well as avoiding stress clamping a warped part.

http://rides.webshots.com/photo/2210296360023244788WvpdgD

5. This time I wanted the manifold left as one pc. for ease of installation. I milled a slot for the blocking plate to minimize welding. The mill should touch all 3 inner walls if a nearly complete seal is desired.

http://rides.webshots.com/photo/2856987050023244788lSAOmr

6. Patience while grinding and filing to blend makes for a much nicer job.

http://rides.webshots.com/photo/2495723850023244788ATCiri

7. The end result with VHT paint cooked on for 30 minutes at 350 degrees.

http://rides.webshots.com/photo/2161711250023244788PcOIEW

Hope some of you find this info helpful.

Curt B.

1952 1300 Canadian 1/2 ton restomod
You Tube