Need some tig welding advice on headers

I need some help on tig welding advice on headers.

I am building a set of headers for my flatty I have everything welded up except at the header flange.

What is the best way to weld the tubing to the flange on the inside. I am using 16 gauge tubing and 5/16" flanges.

I am thinking of using like 1/16" tungsten and 1/16" (er70) filler, 90 amps.

Also should I do the outside. I would prefer not to do the outside but if its best I am thinking about doing Silicon bronze there.

Any tips to make it any easier on me would be greatly appreciated.

Thanks

Nick

 

Definitely a nice Bronze fillet on the outside.

 

If you use bronze . brass .You won't be able reweld steel parts .It is just about imposible to clea n the brass off.it eats into the steel.

 

How can I help from burning through the tubing (16 guage) when welding to the header flange

 

Everything you mentioned sounds great.Weld them on the inside,90 amps will probably be a little hot for 1/16".

 

When I build headers, I mig weld the outside first completly before removing the headers, then tig weld them on the inside.

 

The way I would do it is start your puddle on the flange then move towards the tube so you have maybe 25% heat on the tube and 75% on the flange. If you were really worried you might be able to put a piece of copper rod inside your flange that matches the ID of your tube.

Set up some scrap 16ga and 5/16 plate and try it first.

Al

 

Cut a countersink/bevel on the inside of the header flange. stick a header into the hole, pound the tube out to the countersink/bevel, then tig by directing heat mostly into the flange wipping up to the tube.

 

Manfactured headers are welded on the inside so as not to screw up the chrome etc

 

Definately use Silicon Bronze filler rod.
Miller has a web page on settings for TiG welding.
www.millerwelds.com and enter "Welding Calculator" up in the search window. Really helpful for the size and type of electrode to use as well as the size of the filler rod and how much gas to flow.

Good luck !!

 

x2 ^^^^

 

Thanks everyone for the help I am going to have a go at it this weekend, I will post pics when complete.