Picked up a new project vehicle from Craigslist the other day. Got it for cheap because among (many) other issues, the exhaust had rusted and fallen off. Check out this article for how I fixed it.
The Sawzall is probably an exhaust repair man’s favorite tool. It makes easy cuts through the thin exhaust piping without throwing a bunch of sparks everywhere. This is the one I just got for Christmas and so far it works awesome.
As a side note, the pliers I am using in the picture above are my favorite pliers in the world. I accidentally left them under the hood of my car for a month and was devastated when I couldn’t find them. They are kind of pricey but are totally worth it. Unlike normal adjustable pliers, these ones actually get tighter as you twist on them harder. These things have taken a beating and just keep on going. Check out the reviews on these at the link below:
trick and some WD-40 was what finally got it out.
A tip while welding exhaust. Once you ‘think’ you have it all welded. start the car and hold your hand ~1″ away from the tubing moving around your welds (while making sure not to burn yourself). If there are any other rust holes or spots that you missed while welding, you will be able to feel the air from the exhaust on your hand.
So, my total cost on this repair was ~2 hours, some sweat, and a ~12″ long piece of 2.5″ exhaust tubing. Not too shabby for something that could have cost $100 or more at an exhaust shop.
If you have a MIG Welder, Sawzall and some patience, this is very likely something that you can do at your house on a Saturday. Don’t forget to wear all of your safety equipment though!
Don’t have any tools? No fear, check out my How to get started welding for under $250 guide!