How to Weld Exhaust Pipe – Easiest Steps Ever!

Are you looking for cheap ways to get your vehicle’s exhaust pipe welded? I bet you are. Why else would you be here anyway? Back in my college days, I found myself in the same position as you. I received only so much pocket money that it paid for basic necessities such as food and clothing. Spending hundreds of dollars on welding was beyond my imagination which is why I learned how to weld my own exhaust pipe.

Pinching for the money and making ends meet teaches you some really tough but worthy lessons and skills in life. I regard my excellent welding skills to that. My good friend Ross and I learned how to do it from his dad, and through years of practice, I can now proudly stand on a pedestal and tell everybody that I know how to get my work done.

Welding the exhaust pipe is pretty easy but technical, so you need to follow all the necessary steps besides taking care of all the preventive measures. Remember, practice makes a man perfect, thus the more you practice, the better you get at it. So without wasting any more of your time, let us dig into the details.

How To Weld Exhaust Pipe

Welding an exhaust pipe becomes relatively easy if you have the right tools at hand. And the tools you need depend on the type of welding you are going to opt for. It can be either stick welding, TIG welding, or MIG welding, whichever you are comfortable with. But the technique of welding remains the same. Just make sure that you carefully go through each of the following stated steps to achieve optimum results with no injuries at all because your own safety comes first.

Step # 1: Cutting The Exhaust Tube

Cutting the exhaust tube is the most critical step in the whole welding process because the neater the cut, the better the result. So you will first have to measure and mark the pipe precisely where you want to make the cut because if you don’t do it, the pipe ends won’t fit on each other. After marking the pipe, you proceed to cut the pipe. However, it is imperative to take all preventive measures, such as wearing protective gear ( goggles, gloves, face shield, thick bottoms, etc.) before you proceed.

For cutting purposes, you can use a chain pipe cutter or a hacksaw depending upon your ability to pay because a chain pipe cutter is a lot more expensive and gives a more straight cut than a hacksaw. Remember, you must strive to make a straight cut if you want it to look neat and professional. Once you cut the exhaust pipe, you can use a grinder to smoothen the edges and clear away any dirt that may have accumulated there.

How To Weld Exhaust Pipe

Step # 2: Clamp The Pipe Ends Together

Before you proceed to weld the pipe ends together, it is essential that you clamp them together through some means because if you don’t, you will have to hold the pieces together with your hands. This can cause you some significant injuries, and your hands might end up getting burnt. And you definitely don’t want to go through all that unnecessary pain when you can avoid it altogether.

All you need to do is use the most inexpensive and widely available C-clamps. These clamps hold the pipe ends very tightly and takes up the welding machine’s extreme heat without being damaged. However, fitting the clamps on the pipe ends can prove to be a very frustrating job. You will have to make all the adjustments by hand until the pipe ends look neat and precise before you jump to the central welding part.

Step # 3: Take Small Baby Steps

Instead of welding the whole thing up right away, you are advised to take your time by spot welding through the ends. This is only to ensure that the pipes don’t disengage or bend, and if they do, you will be able to bend them back in place before proceeding further. In this way, you will get a very neatly welded exhaust pipe.

Another reason you should make spot welds, in the beginning, is because the high heat produced from the welding machine may warp the material, but the spot welds warm up the metal, thus reducing the risk of damage. Besides, it also helps prevent gaps from forming in the pipe as you weld it. You can use any exhaust pipe welder we have reviewed.

Step # 4: Go All In

Once you are done with spot welding, the next thing you need to do is fill in any gaps left from the previous step. For this, you will have to weld all around the jointed ends on top of the spot welds. This helps prevent any leakages which may have disastrous impacts. Besides, it gives a nice finished look to the exhaust pipe, which stays in place for a long time.

Safety Measures

As it is said, “Safety comes first” here is a list of some of the necessary precautionary measures that you must take to ensure a safe welding experience.

Safety Measures

1. Always weld the exhaust pipe far away from the vehicle because the sparks from the welding may cause a reaction with flammable materials inside the car.

2. Ensure that you wear a face shield to protect your eyes and face from getting damaged by the welding sparks.

3. Wear thick gloves to protect your hands from burning.

4. You must wear thick pants or overalls to cover the rest of your body from the heat of the welding sparks.


What is the best way to weld an exhaust pipe?

The best way to weld an exhaust pipe is by using TIG welding. This type of welding is infamous for its highly sensitive use on delicate metal surfaces. Plus, TIG welding is considered the best for exhaust piping, so you should prefer this type of welding. However, if you are short on TIG welding instruments, you can also opt for MIG welding.

Is it hard to weld the exhaust pipe?

Welding an exhaust pipe can be tricky, but you can take specific steps to ensure it doesn’t seem too difficult. The first one is practice. The more you have the experience and practice welding the exhaust pipe, the easier it becomes for you to do the job. The second one is the type of welding you opt for. It is a collective opinion that TIG welding is the best for welding exhaust pipes, but MIG and sticks welding can also be used.

How much does it cost to get an exhaust welded?

The cost to get an exhaust welded depends upon the type of welding and whether you are getting it welded by a professional welder or not. The cost also depends on the size of the exhaust pipe area that needs to be welded, i.e., the greater the area, the more the cost. Besides, TIG welding is more expensive than MIG welding, and a professional and highly skilled welder will charge you higher than the ordinary one. But all in all, you should expect a welding bill of up to $500.

What type of welding is strongest?

One of the strongest types of welding is TIG (Tungston Inert Gas) welding. This is because highly efficient tools are used in this type of welding. Moreover, it is renowned for its smooth glide and proficiency in welding even delicate metallic surfaces. All these characteristics come with a price too, which you will have to pay in the form of money.

How long does welding an exhaust take?

Usually, it does not take more than twenty minutes at most to weld an exhaust pipe, but the time may vary with the type of welding you are using plus the practice you have. If you have a great skill set and a lot of practice to go with it, then you may finish welding the exhaust pipe in less than twenty minutes. Besides, it also varies with the conditions in the exhaust. Most of the time, the conditions are less than ideal, in which case it will take longer than twenty minutes to weld it.


I hope I have given you all the knowledge you need to start welding your own exhaust pipe. Practice makes a man perfect, so the more you practice, the more you will be able to brush up on your skills. I agree, the whole process of adjusting and positioning the pipe ends is tricky, and you may end up getting frustrated, but you will learn another crucial skill known as “Learning to persevere.” Just remember to take all the precautionary measures before you head on to the welding business. Better safe than sorry!

About Dave Walker

Dave Walker, a professional welder who has been welding from an early age. Now aims to help others by making them learning skills and finding them new opportunities. He has written for many welding blogs and helped many pursue their welding goals by helping them in choosing the best welding tools of the time.

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