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Installing a new 2-3 inch exhaust pipe on your vehicle can improve your engine’s sound and performance. New exhausts typically make the engine louder, but you can also install exhaust systems that quiet the car down if you want to comply with specific laws in states like California. Plus, if you know how to install an exhaust system, you can replace any part of the exhaust system yourself without needing to get a whole exhaust pipe replacement kit.
While installing a new exhaust can be good for your car, that doesn't mean it's easy. You must ensure you have the right tools for the job and some basic welding knowledge to get started. The good news is that we’re here to help. We’ll cover the tools you need and provide tips for installing a 2-3-inch exhaust system.
Tools You Will Need For Any Exhaust Pipe Installation And Welding
When fitting your vehicle with a new exhaust system, you need the right tools before you start. Ensure you have everything you need before getting started, or you'll end up with a car stuck on the jack stands until you get what you need. Below, we cover the tools you need to install and weld a new exhaust system.
Drill With Wire Wheel
One of the most underrated tools that you can use for exhaust pipe installation and welding is a wire wheel that you can attach to a drill. This tool will help you remove rust and debris before welding the pipe, improving your connection. Also, you can use the wire wheel to clean up the weld once you're done.
Welder
You also need a welder if you want to do some welding. Since you’re only welding exhaust pipes, you don't need the biggest and most expensive welder. You can start with the JEGS MIG 100 Gasless Wire Welder if you're only working with an exhaust system. It's affordable, effective, and comes with everything you need to start welding. Plus, it's gasless, so you’re less likely to hurt yourself. MIG welders are also the easiest for beginners – they're more forgiving.
Welding Helmet And Gloves
Whenever you use a welder, make sure you bring a welding helmet and gloves with you. Without the welding mask, you can damage your eyes, and with sparks flying, wearing thick gloves that can handle the heat is essential. Plus, welding gloves don't run the risk of lighting on fire when you’re welding a pipe.
These tools should be enough to get you started.
Tips For Installation
Installing a new exhaust system is more complex than replacing an air intake. That said, it's something that anyone can manage if you follow some of the tips we cover in detail below.
Measure Everything
Measuring everything is the most crucial tip when installing a new exhaust system. Ensure you measure a few times to avoid installing an exhaust pipe replacement that doesn't fit properly. Always measure multiple times before making any cuts and check to ensure that the exhaust system you purchase is compatible with your vehicle.
Measure the clearance that your exhaust system will have. It should have enough room to not hit into the body or frame. While you can measure for this, you should also leave some additional space for movement because the exhaust flexes and moves when you drive. The last thing you need is a suspension slamming into the exhaust.
Use Clamps And Hangers
When cutting, welding, or replacing an exhaust system, it's crucial to use clamps and hangers. These will keep the pipes still while you work on them. Failing to use clamps or hangers can result in slippage that messes up your cuts, welds, or measurements. Hangers and clamps also make exhaust installation a breeze because they do most of the heavy lifting for you.
Limit Bends And Include A Slight Slope
When modifying your exhaust, you want to limit the number of times it bends. While a single bend or two is acceptable, too many bends will create substantial back pressure that can reduce your engine’s performance.
Aside from bends, you also need to ensure the exhaust is on a slight slope facing downwards as it exits the engine and runs towards the rear suspension. Having the slope assists the exhaust with removing exhaust gases and moisture.
These are some of the best tips to ensure a smooth installation for your exhaust. If you’re worried about getting the job done right, work with a professional to avoid complications.
Tips For Welding
Welding an exhaust is where things get complicated. You can weld an exhaust to fix leaks or replace piping, but some exhaust systems may require welding work to fit properly. Follow some of our tips for welding an exhaust system below for the best results.
Clean The Exhaust Pipe First
Before you weld, clean the exhaust pipe to avoid having a dirty connection when you start welding. Use the wire wheel to remove rust and other debris from the exhaust pipe.
You can also remove rust and debris with solutions meant for removing rust. Always start welding on a clean surface for a good exhaust pipe connection.
Disconnect The Negative Battery Terminal
Whenever you're welding a muffler or exhaust, it's a good idea to disconnect the negative battery terminal to prevent electrical problems. This is because welding metal produces a lot of current that can flow through the vehicle’s electrical system and damage components like the ECU, sound system, and other components.
Use The Right Welding Technique
There are a few different welding techniques that you can use; however, MIG and TIG are the most common for automotive exhaust applications. MIG welding is best for mild steel, but you'll want to use TIG welding for stainless steel because it's more forgiving if you make mistakes. It's also important to note that MIG welding is easier to learn and more forgiving, so it's the way to go if you’re worried about messing up.
Another critical technique tip when welding your vehicle’s exhaust system is a weld sequencing technique. Avoid continuously using the welder around the pipe; instead, weld a few points around the joint and then connect them with shorter welds. This will minimize warping and result in a stronger overall weld. Don't worry about this if you're only welding a small section.
Ventilating The Area Is Essential
Ventilation is also an essential part of welding. You want to use a fan, leave the garage door open, or have some type of ventilation system functioning when welding exhaust pipes to avoid inhaling the fumes. These fumes can be toxic and may even damage your lungs.
Always follow these tips for the best results when welding a two to three-inch exhaust system.
