How to Weld Exhaust Pipe with Stick

Exhaust pipes are integral to the proper functioning of your mechanical equipment. Cars rely on exhaust pipes for smooth operation.

But what happens when your exhaust pipe leaks? Apart from the real risk of CO2 poisoning, there’s a host of negatives from a leaky pipe. And knowing how to weld exhaust pipe with stick and other processes is essential.

On the flip side, getting your exhaust pipe welded with a SMAW process has a lot of gains. If you’re keen to find out everything about welding exhaust pipe through stick processes, you’re in the right place!

And that’s not all!

Right here, pressing questions related to effective stick welding get looked at. With all these facts, putting your exhaust pipe together in a jiff becomes a sure breeze!

Exhaust Pipe Stick–Welding 101: Step-by-Step Info for an Excellent Join

Pipe preparation

First off, you need your exhaust pipe prepped for the best possible join. In the preparation process, you’ll have to do these three things;

Leak inspection

You need to check out affected areas of your exhaust pipe to determine the extent of damage. If a simple leak is the problem, a simple spot weld could be a valid solution. But leaks in several spots and much larger tears require extensive work.

Cutting affected area

With a pipe cutter, hacksaw, or other efficient cutting tools, slice through the pipe, cutting off its affected areas.

When cutting the faulty section of your exhaust pipe off, it’s essential to create a flush joint. Ensuring both workpieces ends fit properly makes your job a whole lot easier.

Workpieces prepping

After cutting, smoothen both workpiece ends to ensure a perfect join. Cleaning your workpiece ends can become easy with a metal grinder or sandpaper. Sand down rough ends and areas close to the weld point. Engaging this practice promotes weld neatness and prevents weak spots.

Workpiece clamping

Using a C-clamp, tightly lock both workpieces in position. During this process, make sure your workpieces are flush all-around. Without assuring a perfect clamp, chances of a perfect, leak-proof weld become slim.

Tack welding

After preparing your stick welder, next is to join both workpieces with temporary tacks.

Neatly tack four to eight spots around the exhaust tubing. Four tacks should be at a 90º angle round. Eight tacks should be at 45º intervals. Tacking several areas around your workpieces enhance full welding ease.

Full welding

Using your stick electrode, join both pieces using spot welds throughout. Lots of exhaust pipes are a bit thin, making a spot weld ideal. Ensure all areas get properly joined to avoid leaks and further tubing damage.

Pros of Stick-Welding Your Exhaust Pipe

Dirt-cheap price

Many welding processes cost a killing to put together. But when it comes to stick welding, there’s a marked difference. Setting tools and required items for stick welding is a lot cheaper and delivers outstanding results nonetheless.

Low sensitivity potential

Stick electrodes possess a very low sensitivity index to dirt, coatings, rust, and dust. With such significant operating ease, welders with varying skill sets will find stick-welding a lot comfier.

Multi-environment support

Unlike other metalwork processes where there’s an urgent need for calm conditions for excellent results, stick welding stands out.

You can conveniently use stick welding in incredibly windy conditions. And there’re very few processes you can say the same about when it comes to outdoor welding.

Downsides of Stick-Welding Exhaust Pipe

Excess electrode use

There’s a higher chance of using multiple electrodes during a pipe-welding session. But in most cases, a welder’s skillset is pivotal to how many electrodes get used during join operations.

Increased spatter potential

Spatter from stick electrodes remain among the most noticeable and may lead to injuries. Welders without proper safety gear should endeavor to steer clear of stick welders.


Too much slag from stick welders could result in adverse effects on your exhaust tubing. With the presence of excess slag, your weld could develop pores in several areas. A massive pore count leads to enhanced leak potential, ruining your weld in the process.

Safety Hints When Using Stick Electrodes for a Safe, Efficient Join

  • Use required PPE
  • Ensure adequate ventilation before firing up your welder
  • Do your best to avoid fumes to enhance safety from zinc poisoning
  • Set your welder to a low amperage range for better stick electrode results. Also, keeping a low amperage range keeps your exhaust tubing in great shape
  • Remove exhaust from the vehicle before embarking on any repair effort. You stand the risk of explosion if you don’t

Read Also>> 5 Best Ways To Weld Exhaust Pipe Like A Pro


What angle should you weld at?

Perfect welds can get put together with your stick electrode placed within 50º – 70º. In most cases, the angle and placement of your workpieces also determine your welding electrode’s angle.

Flat workpieces can get perfect welds at a slightly steeper angle. Any electrode within 40º – 45º could deliver excellent welds too.

Do you push or pull with a stick welder?

Stick welders deliver better results when their electrodes follow a pull pattern. The drag pattern limits slag interference and enhances join quality.

What kind of weld is used for exhaust?

Gas processes such as MIG and TIG processes can properly join exhaust pipes. Other less-tasking methods such as SMAW and FCAW methods also join exhaust pipes with relative ease.

Can brazing be used for joining exhaust pipes?

Brazing offers decent join potential for exhaust pipes but doesn’t guarantee long-term join quality.

Are there no-weld solutions to joining exhaust pipes?

  • Brazing
  • Epoxy
  • Exhaust tape

Last Piece

After this tell-all read, knowing how to weld exhaust pipe with stick electrodes has never been so comfortable. Join up your pipes with relative ease, and get the performance from your car without hassle!

And with the info at your disposal, it becomes more natural to join exhaust pipes regardless of your skillset.