Fabricating exhaust parts is not something that you will always need to do but when you do need to, it’s good to have the right tools and know how. In this video I fabricate the ‘A’ pipe on my 1993 Acura Vigor. The OE part is no longer available and if it was it would be VERY expensive. I could not find the part in the aftermarket either. That meant that I had to make my own pipe. Through a combination of cutting, grinding, heating, and welding, I was able to make it happen. It may not be pretty, but at least it’s quiet. With a little more practice with my welder I think I’ll have this. No matter what, I hope the information in this video can help you if you’re confronted with a similar situation. If not, I hope you’re entertained by the video as you watch me learn how to weld exhaust pipes.

Camera: Brian Kast

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Angle Die Grinder: http://www.jbtoolsales.com/ingersoll-rand-301b2mk-air-angle-die-grinder-2-kit/#oid=1002_1

Sawzall without a chord: http://www.jbtoolsales.com/milwaukee-2620-21-sawzall-recip-kit-with-battery-m18/#oid=1002_1

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Due to factors beyond the control of EricTheCarGuy, it cannot guarantee against unauthorized modifications of this information, or improper use of this information.  EricTheCarGuy assumes no liability for property damage or injury incurred as a result of any of the information contained in this video. EricTheCarGuy recommends safe practices when working with power tools, automotive lifts, lifting tools, jack stands, electrical equipment, blunt instruments, chemicals, lubricants, or any other tools or equipment seen or implied in this video.  Due to factors beyond the control of EricTheCarGuy, no information contained in this video shall create any express or implied warranty or guarantee of any particular result.  Any injury, damage or loss that may result from improper use of these tools, equipment, or the information contained in this video is the sole responsibility of the user and not EricTheCarGuy.

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33 thoughts on “Fabricating Exhaust Parts -EricTheCarGuy”
  1. This man is very professional with all kinds of tools , speaking very good English, his career should be a TV star instead of a fabricator.

  2. I bought a junk yard car about a year ago.b it's builds like these that really expand yoyrnprobl solving skills. Trying to solve a problem for as little money as possible. Normally on higher value cars I would (I am sure you would as well) actually replace the parts with the proper parts. However when you have a cheap/lower value car you don't want to spend the money for the "bolt on" parts.

    Something I learned is to check for alternative parts that will also fit(,not just exhaust) like from different cars. One example of this could be, struts for one car could be $300 each but ones that physically fit but have slightly different valving from another car cost $80 per side. When it's a cheap/low value build the $80 per side looks a lot better when you only paid $500 for the car.

    My cheap build had exhaust leaks, a trip to local auto parts store to the exhaust section and a couple hours of work and now it's quiet for a ton less, much like what you did.

  3. Clean spot to weld doesnt only mean make a shiny metal spot , it also means no oils or other contaminants .. you might not even be able to see any best thing to do is wipe down the surface with a good cleaner that leaves no residue cause residue can also lead to bad welds

  4. Sawing, smashing, and grinding… that’s what working all of the cars I’ve ever owned is like haha

  5. Show those southern boys what a hot wrench can do to rusty bolts!!! Not everyone has the skill or finesse to take apart that rusty sh*t without snapping/ breaking stuff. Nice job!!

  6. Really nice work. Fun to watch a prj turn out so well.

    I know you have thought about this… You could have relieved some pressure on the flex pipe, by fitting before you welded the 2 hole flange to the flex pipe. Had that been in the car and you tack welded the flex joint there… you would have loved the reduction in pipe pressure at bolt in time. its likely the higher pressure on the flex pipe will create a sooner end of life for the flex. 🙂

    Stellar work! Great job.

  7. Would it be possible to cut a new flex pipe and just wrap it around the old flex pipe, then clamp it together? Also how about the flex pipe from a plumbing kitchen sink water intake? Could you fix a small hole in the flex pipe with that?

  8. I just saw this video and It,s good intentions. Point1, the double walled front tubing is an issue. I have seen many Suzuki swift catalytic converters destroyed because people had only welded to the outer. Both need to be welded together or the inside may vibrate, fracture and bore through the cat monolith. Point2, an armoured bellows flex is designed to work in a straight line only…cutting the rear tubing at an angle to suit may have negated stress and cat clearance issues.
    Point3, Even a SLIGHT LEAK IN FRONT of the cat can cause air to get in, be burnt and overheat / destroy / MELT THE CAT ceramic monolith (internal honeycomb block). As a side note, the flex in that kind of size in Australia retails for around 100 DOLLARS AUSSIE AND FLANGES A RE AROUND 13 DOLLARS AND GASKETS 7 DOLLARS. Why do the US guys get stuff so darned cheap. As of March 31st 2019. I,ve ben a professional exhaust tech since 1982 but good for you giving it a go. Cheers from the land of Oz.

  9. Good work Eric the car guy mate nice I all way watch your video. Please Eric make video on astra j 12 plate 1.7cdti any thing

  10. My 98 Camry has alot of leaking on the flex pipe and its a small flex pipe so its probably rusted out inside on mine. Blows hot exhaust gas through the mesh and needs to get replaced.

  11. Eric Thanks for all you do. I know that you take a lot of time to do this without a lot of money! You have inspired many including myself to at least try to DIY.

  12. Good job on your welding Eric. Can't imagine how many people need to practice there welding just to be as good as yours. One Question. How did you not set your rag on fire on the flange weld???:??????

  13. I have a 2000 Passat that needed the flex pipe replaced , the old one had an inner pipe running through it but the replacement did not have that ,and now I'm getting a lot of noise

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