1996 2 door flareside TRX KILLER!

[Blmpkn]

Yeah, your problem is that plug looks stainless, they gall when you look at them wrong... if MIG welding those bungs for the most part just leave them empty from my experience

Right on, I'll leave the next one empty. I wasn't sure if it would warp or not.. that's why I left the plug in it. Probably over thinking/worrying.. damn bung must be close to 3/8 thick lol I'm sure it probably won't warp live and learn!

 

[rumblecloud]

I'm hoping that simply running a tap down my bunghole will work well enough...

Although I've never really thought about attempting this, it does sound kinda painful in a kinky sort of way....

(BTW, I'm reposting to the Quote Thread...)

 

[scotts90ranger]

Right on, I'll leave the next one empty. I wasn't sure if it would warp or not.. that's why I left the plug in it. Probably over thinking/worrying.. damn bung must be close to 3/8 thick lol I'm sure it probably won't warp live and learn!

Yee, that'll happen... The biggest problem with O2 bungs is burn through and spatter landing on the inside threads, warpage isn't a huge issue from my experience...

 

[sgtsandman]

They make thread chasers for O2 bungs because of the weld spray issue. I have one for that and to chase the threads when replacing sensors since the threads can get clogged up from exhaust gas residue.

 

[Blmpkn]

Ordered a chaser today as well as the last elbow I need.. fingers crossed I can call the exhaust complete next weekend

Got the 2nd bung welded on today.. no plug this time.. worked perfect.

I can't forget (which means I will) to block off the EGR inlet to the intake before I fire it up. I'll probably just cut the tube in half, slip the bit that screws into the intake off, weld the hole up, and screw it in.. any better ideas?

 

[scotts90ranger]

Yeah, beer can shim under the EGR valve, been there, works fine, was out snow wheeling when somehow the EGR valve broke and caused a bad vacuum leak, that fixed it...

 

[Blmpkn]

Yeah, beer can shim under the EGR valve, been there, works fine, was out snow wheeling when somehow the EGR valve broke and caused a bad vacuum leak, that fixed it...

Awesome.. that's what I'll do!

 

[Blmpkn]

Success more or less. All melted together and finally installed for good. Need to find a tasteful tip to crank on the end.. but its done! Also in the finishing stages of editing episode 2 of my AWARD WINNING 'Ranger revival' youtube series... DONT MISS IT!

The titanium 140 mig I got last year is pretty sweet... however.... I had to be real careful to not have burn-throughs on my butt welds. Even with the heat/voltage bottomed out. I turned the 'inductance' knob down a bit today and it seemed to help some... but as having that third knob is totally new to me... might be a placebo lol.

Also now questioning if I have the o2 bung in the header clocked far enough for the sensor to clear the floor -__- lol. Looks close.

The stainless hardware that came with the header is SUPER SOFT. Might as well be made from noodles. Got it all torqued down fine.. but two bolts required an open end wrench to get and they both started to turn round at a measly 20ft/lb.

I'll get back over there next weekend, hopefully get the rest of it thrown back together and fire it up

 

[scotts90ranger]

One tip for when you're having melt through issues with a wire welder, turn the wire speed up, it'll cool off the pool... I know everyone always says more wire is more amps or heat but that's until a certain point in the ideal conditions window which you can manipulate sometimes... Are you using stainless wire in the machine with shielding gas? One of my upcoming projects is intercooler plumbing for my F350, being intake I want it to be clean so I was going to attempt to TIG the aluminum tube I got...

 

[Blmpkn]

One tip for when you're having melt through issues with a wire welder, turn the wire speed up, it'll cool off the pool... I know everyone always says more wire is more amps or heat but that's until a certain point in the ideal conditions window which you can manipulate sometimes... Are you using stainless wire in the machine with shielding gas? One of my upcoming projects is intercooler plumbing for my F350, being intake I want it to be clean so I was going to attempt to TIG the aluminum tube I got...

I did turn the wire up a little.. perhaps not enough. IIRC the wire knob goes from 1-10, I think I went up at least one notch from what the guide reccomends.. mabey 2.

If I wasn't burning through.. half the time I'd end up with welds that weren't laying as flat as one would hope for visual purposes.. so I was hesitant to turn the wire up TOO much.. mabey I simply wasn't moving quick enough? It's been awhile.. especially welding material so thin. Definitely a little rusty.

I am using stainless wire. Im NOT using the stainless specific mixture of gas though.. idk how much of a difference it would make. I'm gonna be welding way more mild steel than stainless so when I got this bottle i just got the regular ol mixture

Don't you have a spool gun? Somebody here does I'm super interested in getting one for my welder.. being able to mess about with aluminum seems super fun.

 

[scotts90ranger]

I do have the spool gun for my Titanium welders, it works fine, you'll need 100% Argon for that though... It's frustrating as it's picky, I don't think I was running enough gas though... some welds came out perfect, some like bird poo... apparently clean like mad first and preheat to help.

I'd be more experimental with the stainless if I wasn't expecting/hoping it would handle 20psi when I'm done , exhaust would be one thing...

 

[Blmpkn]

I do have the spool gun for my Titanium welders, it works fine, you'll need 100% Argon for that though... It's frustrating as it's picky, I don't think I was running enough gas though... some welds came out perfect, some like bird poo... apparently clean like mad first and preheat to help.

I'd be more experimental with the stainless if I wasn't expecting/hoping it would handle 20psi when I'm done , exhaust would be one thing...

Spool gun able to do intercooler pipe? Or would that be too tricky

 

[Blmpkn]

 

[Roert42]

Aluminum takes a lot of amps, due to it be highly conductive, that’s why it’s so difficult to weld. Using 100% helium helps cut down on the amps needed.

 

[scotts90ranger]

Spool gun able to do intercooler pipe? Or would that be too tricky

Spool gun is pretty much just for aluminum and wire that just isn't structural on it's own, IE you can't push aluminum wire like you can steel (it would get caught up in the liner not to mention contaminated by the iron), they make push/pull guns but that's out of my element... I think I have a spool of stainless wire somewhere I'll find, I brought it up on a forum with more welding people and I got talked more into TIG... I figure I'll learn this winter, I got a 3" stainless DIY exhaust kit so there's going to be extra material to practice on...