While welding is straightforward, melting two metal pieces to join together into one, different thicknesses and varying methods insert a degree of difficulty.
One of the more challenging aspects of welding is doing it on thinner sheets of metal, such as car parts fabrication. In particular, we will be talking about welding car exhausts.
Car exhausts are steel pipes and are notorious for their thinner walls that make it easy to burn holes when welding, especially if you do not have the right equipment.
We got your back on this one because, in this article, we gathered all the information you will need when it comes to equipment for welding exhaust pipes.
What Type of Welder is Best for Exhaust?
TIG welders have always been the go-to for sheet metal fabrication work and are generally used in car parts, particularly the exhaust system.
The challenge is choosing from the hundreds of brands and models available in the market today. We aim to help you narrow down your search for the welder that will work for your needs.
With this, we give you a list of the most recommended welders for a vehicle exhaust system, starting with the comparison chart below.
| Band/Model | Welding Process Type | Output Amperage | Input Voltage | Weight | Dimensions | |
 | W Weldpro MIG200GDsv | Multi-process (Mig, Lift, Stick, and Tig) | 200AMP Max | 110v/240v 50/60 Hz | 30.4 Lbs | 17.72 x 8.66 x 14.96 inches |
 | Lotos Technology TIG 200 1H-4HPT-NF6E | TIG & STICK | 200AMP Max output | Auto dual voltage / dual frequency (110/220-volt 50/60Hz) | 58 Lbs | 28 x 13 x 17 inches |
 | W Weldpro TIGACDC200GD | TIG & STICK | 200AMP Max output | 110v/240v 50/60 Hz | 53 Lbs | 17.6×7.9×16 inches |
 | Primeweld TIG225X | TIG & STICK | 225 Amp Max output | 110v/240v 50/60 Hz | 90 Lbs | 24 x 19 x 12 inches |
 | Lincoln Electric Square Wave Tig 200 | TIG & STICK | 200 Amp Max | 110v/240v 50/60 Hz | 73 Lbs | 22 x 13.1 x 21 inches |
These 5 welders are by no means considered because of their price or brand, but rather on their feature set and the value they offer in their price point.
Our favorite pick among these is Lotos Technology’s TIG 200GD. We will go through numerous reasons, but for starters, the Lotos TIG200GD is by far the most feature-packed and the easiest to use on the list.
Things to Consider Before Buying a Welder for Exhaust
One thing to note is that, while there are many welding methods out there, there is no single welder that is suitable for all applications.
The success of your projects will involve the correct combination of equipment and skill. You take care of the skill part, and we will give you the lowdown on the tick boxes you need to check when choosing your TIG welder for exhausts.
The pulsing rate
TIG welders are popular because of the higher level of control it gives the welder in terms of heat applied as you work on your project. Most modern TIG setups are capable of higher pulses per second, and most can be controlled on the fly as well via a pedal.
This pulse is extremely important for fabricating thin metals as well as those with odd shapes and bends.
The inclusion of a foot pedal
In welding exhausts, the welder will often find himself welding in awkward positions, all the while holding the filler rod and the torch.
This makes a foot pedal an essential tool to control the heat you apply to the metal on the fly as you weld. This is critical especially if you are welding a project where aesthetics are also considered and the weld will be visible.
Portability of the setup
For a TIG welder set up to be considered portable, it has to be in the 40-50 lbs weight range. This is important especially if you need to move your welder around your home or shop.
Larger setups will require a cart for you to lug it around even within the shop. However, for exhaust welding purposes and small projects, those within the 40-50 lbs range are more than capable.
Budget and warranty
Budget is also a consideration especially if you are just starting up on your welding career. It all will depend on what you will be using the machine for and how heavy of a usage it will be facing.
Look for a machine that offers more features versus the amount of money you will be paying for it.
In terms of warranty, look for machines with at least one year warranty at the minimum. If you are expecting heavy workloads, go for those with 3-year warranties attached to the purchase.
Our top five welders for exhaust welding
LOTOS TIG200
Stand out features:
- Multi-material welding capabilities and is especially capable with welding aluminum and stainless steel.
- Multi-process TIG and stick allow extra flexibility in applications.
- Automatic dual voltage input allows the machine to be used in conventional and residential power outlets.
- Precision control over applied heat via the included foot pedal which gives extra clean and accurate welds on aluminum and stainless steel.
- The duty cycle is among the most efficient at 60%/100% which means more time to work on continuous welds before the mandated cooling period.
Lotos welders are known for their duty cycle and reliability in delivering accurate and clean welds in materials.
The one thing that sets this welder apart is its mid-level price while still offering full accessories and all the features you need.
Its sturdy aluminum construction, as well as the location of the controls on one side, allow it to be extremely maneuverable around the shop.
The machine switches automatically from 220 to 110v as well as having both TIG and stick processes available.
Its powerful built-in cooling system allows duty cycles of 60% for 110V at 150A/220V at 190A and 100% for 110V at 110A/220V at 150A.
Pros:
- The kit comes with complete accessories
- Dual voltage as well as dual frequency
- Comes with a 30-day refund guarantee and a 1-year warranty
- A detailed manual of instruction
- Unbeatable price-performance ratio
Cons:
- The included foot pedal may take a longer learning curve to use
- Its cooling system sucks up dust inside the chassis
Weldpro MIG200GDsv
Stand out features:
- Super-compact build at just over 30 lbs, makes the rig extremely portable, facilitating ease of use and storage
- This machine can do MIG, Flux Core, and TIG welding processes
- Has a VRD high-temperature display and overload protection for increased welding safety
- Large LCD screen for accurate adjustments of spool speed as well as AMP adjustment
- Easily switch from AC and DC mode, allowing versatility in welding different materials.
The Weldpro 200 is considered a flagship portable machine from W Weldpro and is proudly made in the USA.
This machine’s multi-process capabilities make it a practical choice and offers extreme value for the money especially for beginners, who can use this to practice their craft on specific processes.
Aside from the price, this is also an IGBT circuit-equipped machine, making it quite efficient. With its AC/DC TIG welding capabilities and the Weldpro 200 is a solid choice both for beginners and professionals alike.
Pros:
- Great for both DIY and professionals
- Great value for money with its multi-process capabilities
- Small, compact, and lightweight
- AC/DC TIG welding features
- Large and bright LCD screen that’s easy to read even in sunlight and bright shop lights
Cons:
- The spool gun is not included
- There is no foot pedal
Weldpro TIG200
Stand out features:
- Can be used on both simple DIY projects as well as professional-grade jobs
- Includes a robust and solidly built foot pedal as well as a trigger-equipped torch for awkwardly positioned projects
- Packs enough power for heavier and thicker metal panels
- Easy to use digital control panel and swift start-up
- Better than most duty cycles when maximum settings are set at 240V, the Weldpro duty cycle for AC TIG welding is 40% @ 200A, DC TIG welding is a little better, 60% @ 200A
What separates this welder from the rest and rare at this point is the fully digital control panel. Old school welders may have some difficulty adjusting to the absence of knobs and dials, but for some, it is a godsend and becomes more of a personal preference.
The foot pedal is done in a rocker-style configuration, with enough weight to keep it in place. This welder is also equipped with a highly efficient IGBT inverter but is quite a handful at 60lbs.
Pros:
- Fully digital touchpad controls
- Affordably priced much lower than similarly featured welders
- The rocker-style foot pedal included in the package
- Comes with a full 3-year warranty
- Inverter based welder for added efficiency
Cons:
- Ground clamp feels inadequate and flimsy
- The absence of knobs and dials may take some getting used to
PRIMEWELD TIG225X
Stand out features:
- Multi-material capacity means it can be used on stainless steel, aluminum, and alloys
- Built-in powerful cooling system means less likelihood of overheating
- The torch and included pedal are made in the U.S.A.
- IGBT inverter and PWM modulation make it power efficient
- Works on both AC and DC voltage as well as 110 and 220 volts
The Primeweld TIG225X is an interesting machine as it is made in China but its accessories are made in the U.S. This combination makes it one of the most affordably priced TIG-capable welders with full features, costing just a fraction of similar machines.
However this machine is on the heavier side at 90 lbs and as such, built with a sturdy handle to easily move it around.
Its versatility is evident in how you simply flick a switch to go from AC-DC and also to 110 and 220v.
Equipped with a powerful cooling system, it packs more than enough punch for work around the house and light projects.
Pros:
- Excellent customer support and 3-year warranty
- Equipped with IGBT inverter technology and Pulse-Width Modulation
- Intuitive dial and knob-based controls for adjustments
- Solidly built chassis ensures longevity
- Dual voltage and works on both 110v and 220v
Cons:
- May need water cooling for heavier duty workloads
- The included pedal could need an upgrade
Lincoln Square Wave TIG 200
Stand out features:
- This welder is a multi-process machine that can both handle AC/DC TIG and Stick welding
- This machine also is the recipient of the 2015 Global Media Award
- Comes with bonus accessories
- Can handle both stainless steel and aluminum
- Can be used almost anywhere with its dual voltage capability
This welder is just the right combination of feature and price, which places it in the middle in terms of pricing.
The advanced, yet easy-to-use features make it appealing to both beginners and professionals alike. Thanks to inverter technology, this machine packs a powerful punch and provides a single power source for both TIG and Stick welding.
The compact machine only weighs 47 lbs and is small enough to fit in a backpack.
The Square Wave Welder also features adjustable amperage, voltage, AC frequency, and pulse frequency. In addition, the welder can weld a variety of materials, making it a great value for the money.
Pros:
- The included TIG torch has a built-in flex head
- Clean and refreshingly simple to use controls
- Lightweight and portable at just 47 lbs
- The 3-year warranty
- Inverter technology allows the welder to be compact and efficient
Cons:
- The minimum 10A output may be too high for some welders
- The ground cable is a bit short
Conclusion
The list above is not an exhaustive one, but each one covers all the basics of what you will need in a TIG welder setup.
The takeaway is that successfully welding exhausts depends equally on the equipment as well as the skill of the welder.
You can invest in the most advanced, the fanciest, and the most expensive equipment money can buy, but equally important is to invest in your skills as a welder as well.
Exhaust Welding FAQs
📌 What is the best welder for thin metals?
The preferred welding process for thin metals is TIG welding because of its precision and clean look. TIG has minimal or almost zero burn through and the user has more control on the energy input via the size of the electrode as well as the pulse rate.
📌 Is it hard to weld exhaust pipes?
Exhaust pipes are among the most challenging to weld because of their shape, the thin metal, and the fact that most of the material is stainless steel. The shape also varies because of the ways it snakes up underneath. It is also dependent on how old, how rusted, and what the overall condition of the exhaust system is.
📌 How much would welding an exhaust cost?
Considering removal, prep work, and the actual welding itself, it could be as much as $200. This would include about a couple of hours of labor. It is advisable to get quotes from various shops. But if you have a welding machine and the skills, it is ultimately cheaper to DIY.
