Help with making an exhaust flange please.

[paul r]

Hi,

I need to make up some exhaust flanges like the one in the attachment. Can anyone tell me how to do this? the pipe is 2 1/4 inch, I will be making mine out of mild steel.

How would I make the 'fluted' part and keep it all tidy?

Cheers,

Paul.

 

[Furry Freak]

Well one option would be to look at the ready made range on jetex. They deliver, fast and have some good parts. I made up my whole exhaust from their bits in 2 1/4 inch.

FF

 

[paul r]

Well one option would be to look at the ready made range on jetex. They deliver, fast and have some good parts. I made up my whole exhaust from their bits in 2 1/4 inch.

FF

I couldnt see any kind of flange like that on jetex

Paul.

 

[Furry Freak]

No, I meant buy to mating flanges, cut the end off you original pipe and make a new joint completely. Not seen the pipe in context so apols if that won't work. Or I'd do a straight overlapped joint with a sleeve.

FF

 

[paul r]

No, I meant buy to mating flanges, cut the end off you original pipe and make a new joint completely. Not seen the pipe in context so apols if that won't work. Or I'd do a straight overlapped joint with a sleeve.

FF

I see what you mean. No, that wont do. I'm making de-cat pipes so the pipes I make have to match the original with regards to flanges....

Paul.

 

[hotrodder]

Any exhaust fabrication shop should be able to make the bits you need, quite a few of the tube benders used in the exhaust fabrication weld incorporate swaging kit for flares like in the pic as well as expanders for simple parallel slip fit joints.

Could be done with nothing more than a hammer and something suitable suitable to hammer on like a chunk of bar stock etc but really not worth the effort involved

 

[paul r]

What about cutting a piece of sheet metal out and wraping around the pipe, then welding it?

Could calculate the shape of the cut out with the mitre program mentioned in other threads??

Cheers,

Paul

 

[hotrodder]

Presumably the flared piece needs to be at least 16swg to cope with the pressure from the slip over bolted flange? Unless you own a suitable set of slip rolls be easier to reshape the end of a piece of tube (or a concentric reducer which is already half way there shape wise) . Even easier to get an exhaust shop to make 'em, literally takes seconds to make with the right kit so should be no more than their min labour charge. Where abouts in the UK are you?

 

[busastars]

From what I can make out its just a cone on a pipe. Use the free cone software to print the flat piece of metal, roll it, that small be easy by hand also have a pipe to attach it to.

Job done, thats if im reading the post right.

 

[paul r]

Presumably the flared piece needs to be at least 16swg to cope with the pressure from the slip over bolted flange? Unless you own a suitable set of slip rolls be easier to reshape the end of a piece of tube (or a concentric reducer which is already half way there shape wise) . Even easier to get an exhaust shop to make 'em, literally takes seconds to make with the right kit so should be no more than their min labour charge. Where abouts in the UK are you?

I'm in Crewe, cheshire...

Paul.

 

[paul r]

From what I can make out its just a cone on a pipe. Use the free cone software to print the flat piece of metal, roll it, that small be easy by hand also have a pipe to attach it to.

Job done, thats if im reading the post right.

Yes, thats exactly what I was thinking.......Would it be strong enough with the weld at the bottom of the cone though?

Paul.

 

[series2]

If it's just a one off, it can be done quite easily with a a pair of mole grips or pliers, a ball pein hammer and a vice. have a look here.

I did this to remove the centre box on my Sahara, took about ten mins to do!

 

[busastars]

Yes, thats exactly what I was thinking.......Would it be strong enough with the weld at the bottom of the cone though?

Paul.

Maybe, maybe not. Ive built 2T exhausts from 0.8mm mild and once there rolled there very solid. From what I can see in the pic even if it was not strong enough then would be easy to doubble up or brace.

I would gess an hours job tops.

 

[JayRS4]

Do it the same as Sam did with these http://www.mig-welding.co.uk/forum/showthread.php?t=10409&highlight=thistles if youve got any kind of press, or even a large vice it`ll be an easy job.

 

[paul r]

Do it the same as Sam did with these http://www.mig-welding.co.uk/forum/showthread.php?t=10409&highlight=thistles if youve got any kind of press, or even a large vice it`ll be an easy job.

That looks simple to do.....where would I get the metal former to press into the exhaust?

Paul.

 

[paul r]

That looks simple to do.....where would I get the metal former to press into the exhaust?

Paul.

Looked on ebay and cant find anything like this.....is it something I would have to get made?

Paul.

 

[JayRS4]

I think you`d have to make friends with someone that has a lathe. You might even get away with a hard wooden (beech etc) former if that opens your options up.