How to Weld an Exhaust Manifold

Lead Image
  • 2-6 hours
  • Intermediate
  • 50-125
What You'll Need
Tool Set
Wire Brush
Safety Goggles

Knowing how to weld an exhaust manifold can be a great advantage. The job of welding the exhaust manifold is not an easy job, but with the right tools and this guide you will be able to weld your exhaust manifold and save yourself money. With proper preparation and planning you can execute the job like a professional. Here’s how to go about doing it.

Step 1 – Getting Started

Make sure your eyes and body are adequately protected. It is very important that you take into account all safety precautions when working with any electrical equipment.

Step 2 – Space and Light

Move your vehicle to a place where there is enough space for you to work. There should also be sufficient lighting in the area where you are working. Do not try to work in a dimly lit room that is full of stuff.

Step 3 – Remove the Exhaust Manifold

You must remove the manifold from your vehicle. Do not attempt to weld the exhaust manifold without taking it off first. Based on the model of your vehicle, this could take you from 10 minutes to an hour.

Step 4 – Clean the Manifold

Once you have removed the manifold, clean it with a cleaning solution. The solution should be able to remove all flammable chemicals and rust.

Step 5 – Use a Wire Brush

Use a wire brush to clean all the tougher deposits and build-ups that still remain. When the manifold is clean, wipe it and let it dry.

Step 6 – Preparing the Area

Use the grinder to grind the area that needs to be welded. The grinding will remove any rust that has built up in the cracks on your manifold. The grinding will also give you a clean surface to weld. Be careful that you do not grind too much.

Step 7 – Use a Wire Brush

If there are some areas where the grinder cannot reach, use a wire brush to clean them. You can also clean the place where you will attach the ground clamp so that you get full power while welding.

Step 8 – Connect the Welder

Connect the welder and power it up. If your welder uses 110 volts, you will need to power it up fully before using it. Remember to use your goggles while working.

Step 9 – Welding

Do not just patch the area, but work slowly to enable deep penetration. When you lay the weld, move slowly so as to create a large molten puddle. The idea is to let the weld get into the crack or hole to seal it completely.

Step 10 – Let it Cool

Once you have finished welding the manifold, let it cool down before attaching it back to your vehicle.

Step 11 – Fixing the Manifold

Mount the manifold on your vehicle and tighten the bolts according to the recommended specifications. Check the gasket. If it is damaged you will need to replace it.

Step 12 – Finishing

Once you have finished fixing the manifold you can use your vehicle.