I hope you know how risky it can be to move around with a car having a broken exhaust pipe. An exhaust pipe is an essential component in any vehicle, responsible for transmitting reaction gases out of the engine. Whether you are a professional repairman or a DIYer, it is good to know how to weld exhaust pipe in a car right in your garage. Most of these engine vehicles come with either one or many exhaust pipes. 

Therefore, you need to understand how to repair it when it has complications using this salient information from weldingHubs.com site. This website carries everything that you may wish to know concerning the welding procedure or process. Remember, this welding an exhaust pipe is not difficult, but you need to have the necessary knowledge to successfully perform the task. 

How to weld exhaust pipe on car step by step guide

I will take you through a precise step-by-step guide on how to weld exhaust pipe in a car. Doing yourself will save some money that you could use for a professional maintenance specialist.

Therefore, any standard MIG welder for auto body work welding process needs only 4-6significant steps, but there might be other issues for you to fix during the process. 

Equipment and materials

To succeed in welding your exhaust pipe, you should assemble some necessary materials with you. Some of these requirements include; hacksaw or chain saw, exhaust pipe, eyeglasses, hand gloves, mask shield, grinder, welder machine, and C-clamps. 

When you have all these requirements, you are ready to go on with the exhaust pipe welding process. 

Step one: Spotting the damage

This step is crucial to help you have a clear picture of the area or part you should weld. Identifying a broken place in an exhaust pipe is simple, especially when you remove it from the engine.

However, you may spot some of the damages with your naked eyes, and you can work on it immediately. Go on if you believe in yourself but, if you are not sure, then call for help or take the car to a professional maintenance specialist.

Step two: Considering safety measures

Now that you have your necessary tools and equipment and know where to weld, it is time to abide by safety measures. You cannot neglect this step because your health is critical, and therefore, put on eyeglasses, hand gloves, and mask shields. 

Remember not to weld your exhaust pipe in a confined place; open place welding is advisable. Besides, you need to be sure of the type of metal of your exhaust pipe. 

Step three: Cutting the exhaust pipe correctly

You have everything in place, and you have already identified the broken part; the next step will be to cut the pipe precisely. Correct cutting and welding of the exhaust pipe determine the success of the process. Therefore, it is necessary to trim the tube, making the line useful, and fix it properly. It would help if you were keen when measuring the pipe; the measurements should be accurate to fit the other tube correctly and comfortably. 

After taking the right measurement, start cutting the tube using either a hacksaw or a chain saw for the pipe. You have the right to use any of these cutters as long as you make straight cuts.

Remember, failure to make precise cuts will waste the pipes and hard fix or fit in the other tube. If you damage, be ready to replace it with a new one, of which it is expensive.

Therefore, you should be keen when cutting the pipe; try as much as possible to make excellent cuts. Sometimes, you may use a grinder to remove paint, dirt, or extra metal from the exhaust pipe before welding. 

Step four: Use the clamp to hold all pieces together

When you are through cutting and cleaning your pipe, it is time to put the tubes together. Using a clamp will spare you from using both of your hands when welding. 

This will reduce the chance of getting minor accidents or injuries. Besides, you will find it hard to fix the pipe using bare hands than a C-clamp. Therefore, use the clamp to hold the tube firmly to have a smooth exhaust pipe welding process.

Before the welding process kicks off, ensure that the pipe joins perfectly. It will help if you fix it correctly because fitting the lines afterward will be difficult. Fix them as you would wish them to stay in the car.

Step five: Spot weld

Spot welding is essential to guide you through the welding process. So, you will have to make five or six spot welds on the pipe to act as a guideline. Because a simple mistake will damage the tube, spot welding is inevitable. Spot weld is also useful when working on a thin pipe; it will prevent it from deforming and warping when the heat is high. 

Also, if the pipe moves, it is possible to spoil the whole welding process by making gaps. Therefore, you will have to spot weld before deepening the exhaust pipe welding process.

Finishing the exhaust pipe welding process

After all the above steps are successful, you are through with the process but, finishing touches are a must. So, it would be best if you welded the tube all-round, filling any available gaps. Remember, any hole will lead to leakages. Therefore, you need to do it correctly to have leak-free incredible welding results.

Frequently asked questions

What is the importance of spot welding in exhaust pipes?

Spot welding is inevitable in exhaust pipe welding as it will prevent thin tubes from deforming and warping when the heat is high. So, you will have to make five or six spot welds on the pipe to act as a guideline.

What are some of the safety measures before the exhaust pipe welding process?

Do not weld your exhaust pipe in a confined place. Also, put on eyeglasses, hand gloves, and a mask shield for your safety.


I thought you should know that exhaust pipes are responsible for driving out harmful or toxic gases from the engine to the environment. So, it would be best if you had a leak-free exhaust tube for your safety. This article on How to weld exhaust pipe in a car should help you repair the line correctly.

Remember, the pipes are also essential to drive out reaction gasses out of the engine; this cools down the machine and extends its lifespan.