TFS: That's How They Make Merge Collectors

[@NickFerry]

4:43 - that homemade die is genius and so satisfying

[@MakeSomething]

This was great! Learned a ton. I found myself saying "I could make a jig to do that if I needed to." Great inspiration!

[@idriwzrd]

A few of those scenes triggered suppressed memories of me vs. the family court industrial complex, only there was a lot more lube involved here.

[@normhowes2975]

I only started sitting down a few years ago from the mid 80's so I know your pain!!!

[@BillPhillips4]

The format of this video reminds me of the "how it's made"television program, without all the chatter... Nice!

[@DouglasClaude]

Been awhile since I've heard a not-so-bad techno ditty. This reminds me of the tv program "How it's made"; I love seeing how things get manufactured - keep 'em coming!

[@Pistonstrokes]

It makes sense now, these guys were the kids back in the day that were trying to fit a square in a circle hole. Touche kid, you're now a fabricator.

[@Ilsabug1]

LOL

[@altonb93]

Where does the circle go? Thats right the _square hole_

[@Krzywoprostydezerter]

Is that a problem?

[@Pistonstrokes]

@@Krzywoprostydezerter the opposite

[@Krzywoprostydezerter]

@@Pistonstrokes It's not a math lesson for seven years old child. You are a MAKER, use your imagination✌🏻Peace

[@brucer81]

Amazingly simple but incredible none the less. I guess it's all about having the right tools. Thanks for bringing it to us.

[@melgross]

Great stuff. You know, we can make those machines. They’re really simple (except for the bandsaw.). Even the hardening and tempering of the dies is simple.

[@lasersbee]

Very interesting... Could watch a lot more of this stuff.

[@em21701]

Today I learned that exhaust tubing is shaped on a logsplitter with specialized dies.

[@liebherr11602]

Was thinking that my 30t splitter is under utilized

[@jlunn900]

My mind is blown!

[@DarkLinkAD]

I bend it with my OG farmer hands, like a clown tiein balloon animals

[@luisg1653]

That was really fun to watch. Now I'm wondering if I could get a swedge bit and use a simple hydraulic press to expand exhaust piping.

[@heyallenify]

A friend of mine has used a port-a-power type hydraulic system and a generic pipe expander to expand pipe for his tractor and pickup. He may have had to make a new mandrel, I seem to remember that the stock one didn't survive after a while, but that may have been using it with an impact driver before he switched to the hydraulic setup.

[@goodlydanz]

It's always awesome to watch the process of things being made that you buy already assembled

[@Jordan-9093]

Love that bandsaw!!!!

[@GizFab]

The thing thats always got me confused is how they properly seal those non-slip style 4-1 merge collectors. I'd imagine is not fun welding in between all the runners once in place.

[@177SCmaro]

You weld the runners together first, then slip the collector over and finish the weld.

[@saab9251]

This exactly. I just built my first set of headers last week and it honestly wasn’t that bad. I cut a small piece of metal to fill the area between the tubes and then tig’d them all together. Then I ran a short head up the outside between each pair of tubes, slid the collector on and welded around and down to the side beads. Honestly wasn’t nearly as bad as I figured it would be.

[@gino27224]

I personally don't mind more of these. I learned something and I was quit entertain. 👍👍

[@joecool5034]

Already knew this information but fun to see in video form. I like the "how it's made" feel. Keep'em coming bro!

[@kevincollins2184]

Good timing I'm going to be starting a header build this weekend so the more input the better

[@renerostohar]

Whay you do not use backgas whis welding the y pies, you will get suckering or not?

[@tomwagemans1872]

Nice to see that the shop has some pretty nice homemade stuff for fabrication.

[@TheFabricatorSeries]

Yup! It's an eye opener for sure. They make their own dies and equipment to manufacture. It makes you step back and really think about a product. That blue forming machine is completely custom made.

[@stevenmitchell6347]

If I had that equipment in the 80s, custom exhaust systems would have been much faster and easier to fabricate! Good to see the simplicity of the tools. 👍💪

[@DodgyBrothersEngineering]

Nothing cutting edge about the tools they used. They could have been simply fabricated in the 80's. What was missing was the thinking outside the box.

[@stevenmitchell6347]

@@DodgyBrothersEngineering The availability of mandrel bent tubing in the 80's was virtually nill. I fabricated custom exhaust systems in the early 80's and even stainless steel tubing was unobtainable to the small shop because of "minimum quantity" requirements. Modern inverter TIG didn't exist and MIG wasn't that widespread. FluxCore was used in industry, I used it building offshore oilrigs in Freeport, TX but small, affordable rigs weren't available to the general public. There has been a boom in equipment availability at affordable prices over the past 40 years. I became an Industrial Design Engineer and really appreciated access to equipment I could only dream of years earlier! I was one of those "out of the box" thinkers thanks to my early years of hands-on problem solving before my degree. I agree with your basic premise but one can be limited by what is actually available at the time.

[@EcoMouseChannel]

The machine was literally just a double acting cylinder. The mandrels were totally custom made. You could make that stuff! The Huth swager is also just a pull ram, and you can buy the expanding mandrels, no big deal there. However, I do like the swage box those have for compressing the tube ends. Always yields a stronger tube than an expanded joint. But those are really sold to exhaust guys, and they don't really care too much about tube strength, just more about ease of fit up during installation.

[@issacmuckelrath5541]

Could sit and watch that all day!!!

[@kenjackson4177]

Can you please do a short safety video on the dangers of Chlorinated Brake Clean and TIG welding and the production of Phosgene Gas. We all need to be made aware of this. Thanks

[@chuckingram5966]

They only showed how they made two into ones I used to build four into one merge collectors using 21° bends and a band saw cutting each one length wise one at a time it was a lot of fun

[@Flowsalvador]

Time fly seeing your videos...!!! Thanks.

[@kerrygatling663]

Interesting video there's nothing like having the right tools for the job.👍

[@grantbyrd4273]

Could you possibly go into welding header tubes into a merge collector? All these videos i find show how to make the merge collector however they never show how to weld each tube into one.... I assume you weld one by one but the last one in a series of 4 tubes you could only get possibly 1/2 the tube welded successfully.

[@Brandon-ju7cm]

for a 4 into 1 collector you would either patch the center where the 4 tubes meet (or merge spike) and run welds up the legnth of the tube, so when you put the collector on you can see the weld in the "vee" to tie it all together.

[@smevox7490]

Great vid!! Would love to see how a turbo manifold collector is welded, seems like a pretty skillful aspect of manifold making.

[@normhowes2975]

I believe I've watch TFS making what your looking for.

[@smevox7490]

@@normhowes2975 oh cool I'll check it out. In a new sub here :) great channel

[@smevox7490]

@Anthony what? Lol

[@smevox7490]

@Anthony no it's not a cast side. I'm talking about custom tube manifolds. Nothing is cast in what I'm talking about.

[@IDBSNOSTONERS]

I used to work at an exhaust shop they had that same bender/expander/reduced tool pretty sweet gig tbh

[@richardsolomon8076]

Cheers JDC for the walk around, Great video Justin.

[@hiteracing1489]

All that was awesome, it pays to have the right tools

[@JustVoss]

The How It’s Made music was on point 👌

[@42Fab]

I like these sort of focused behind the scenes videos!

[@geneva760]

I fail to see how anyone can give this a thumbs down -- the guy is talented and doing something involved with something we ALL enjoy - MOTOR VEHICLES (HA - and MOTORBIKES and PISTON ENGINED aircraft) - obviously car haters accidentally viewed this video. Have a nice day all. CHEERS from AUSTRALIA.

[@Poverty_Welder]

The stickout to get in that tight space must have been pretty insane, were they purged?

[@shitbox7413]

Alpha Utahn, Wide cup. 👍🏻

[@custardavenger]

That's what I came here to fins out, how the hell did the complete the weld on the 2-1? Would love to see a video specific on that and getting into really tight angles.

[@stevejanka361]

Good morning, who said there are no craftsmanship in the USA? These guys redefine the meaning of the word. Can you say World Class, they are. Thanks for a great video. Take care and have a Merry Christmas and Happy New Year.

[@kevinhgreaves]

I could watch this stuff all day, but work gets in the way

[@andycollins8685]

That was awesome... even showed me a different way to hold my tig torch... win win!!!!

[@afterhoursfab]

Very nice, I love how its made videos. Also I was just watching Fireball Tools shop tour and he had a very similar bandsaw, neat.

[@efimsutyagin4691]

That were awesome! Thanks for the hints!

[@flyasshooptie]

Amazing as always. I really.nerd out watching all the processes involved in making all the products that make our lives easier as fabricators, as well as improve the quality of our work 😁👍🏼

[@gordowg1wg145]

Looked like they were welding SS, and the apparent sugaring would support that - not important for the application? I thought you had already made some up, but those were more transitions, checked 6061 (another very cool welding site) and still nowt - I'm sure I've seen a few, but...

[@5tr41ghtGuy]

Great video! It appears most of the skill was coming up with the process and special tooling. And the TIG welding.

[@retep8891]

I feel like it the only thing the video was missing was "how it's made" like commentary on what was going on.

[@TheFabricatorSeries]

Some things are better left unsaid

[@nickb.6884]

Love the video. I love the show how it works as well.

[@Farpointhold]

I am going to make a set of runner boards for my GMC 17 standard cab. I would think many of us are sick of store bought Scamzon look alike product. How about whats your take on it? Your a heck of a welder I enjoy your channel. Thanks. This last one was cool, But to me your about DIY making it.

[@4seasonsbbq]

Great video I always wondered how those were made. Thanks for sharing

[@gekko3487]

Could you make a video about pin stands on a car? Both the stand itself as well as the system on a car.

[@adambergendorff2702]

awesome video, love seeing things being made, not just instruction on how to weld, love all your project videos!!

[@peterseaton4777]

Fascinating insight mate cheers.

[@boboften9952]

B E N D E R B E N D E R B E N D E R Ah ha I'm even greater than what I thought I was .

[@shitbox7413]

Very cool, always wondered how that was done. 👍🏻

[@rifleman7313]

Could you please explain what exhaust pulse pairing between banks is and what advantages it has (guessinh that there are some).

[@Fix_It_Again_Tony]

LOL, love the music.

[@carlwhite8225]

Love it, always wondered how they did that.

[@ron7922]

Great video!...question.. Can a collector be repaired? I have a leak on the inside of the collector. It seems to be square in the middle where the tubes come together.

[@earlcousins6635]

Great Vid! That is an AWESOME band saw! Who makes it? Merry Christmas!

[@gasfiltered]

It's painted DoAll Gray. When that saw was made (early 50s) it looks like, most machines were green. But DoAll weren't the only ones using gray either. I couldn't find any pictures to confirm, but if you're looking at an industrial metal cutting bandsaw made in the last 100 years there's a better than average chance it is a DoAll or a Dake.

[@chrisdrumsw]

I’m 90% sure it’s a Marvel. We have one very similar at the shop I work at, also grey.

[@bigviking0001]

How about showing mandrel bending 4130 roll cage hoops for Rails?

[@grantharkness8937]

Great vid great insight to how it's done in a shop that has all the tools

[@TheFabricatorSeries]

I would kill for that bandsaw... that thing is like 8 feet tall and made out of cast iron 🤤🤤

[@grantharkness8937]

Suggest to Mrs fabricator as a idea for Christmas next year lol

[@joeblough70]

Wow, 2 onto 1 merge ? Try 3-4 or six merge non slip fit. Form collectors hammered on to 4 tubes are science!

[@rixtrix11]

Cool, but pretty old school stuff. I thought this was about a "real" merge collector, with 4 tubes tapering down to a slightly larger size before flaring out to a much larger outlet with an included cone in the center formed by the cuts on the individual inlet tubes, like those sold by Burns Stainless among others. Can't be extremely hard as there are chinese knockoffs for about a fourth the price of a /burns collector, but the way the tubes are cut is the key!

[@ronniepedersen980]

Brilliant thanks buddy

[@fastone371]

Very interesting video, thank you. I just wish that they would have finished that 4-1 merge collector that they started on, thats what I really wanted to see.

[@arnaudtroadec6237]

Merci beaucoup pour cette vidéo dude. Good d'job.👍🤘. Petite question, quelle est le modèle de votre scie a ruban s'il vous plais ?

[@keithparady2594]

That was wicked kool

[@JSFILMS129]

Noticed they didn’t back purge on the one style of collector when final welding, correct?

[@jp360ford2]

I’m gonna expose my inexperience here but what about the gaps around where the four tubes go into the collector?? Or is there enough exhaust scavenging there’s no backflow of exhaust?

[@TheFabricatorSeries]

Suggest a future episode and check out some links to support TFS! Learn to TIG Weld in Our Classes - thefabricatorseries.com/classes 10% off at Weld Metals Online - weldmetalsonline.com/?ref=TFS Tools & Gear We Use and Recommend - www.amazon.com/shop/thefabricationseries

[@SWhite-hp5xq]

Enjoyed it mate.. cheers

[@darripeclement7006]

What is the angle tube bending ? 10 degrees ?

[@youngmango4508]

Dope af. Would love to work there

[@jimfryar1]

That’s pretty cool, especially since, in the future, I’m gonna try to make a one off, 4 into 1 collector (4-2 1/4” pipes into 1- 3 1/2” collector) for a project I’m doin. Gonna try to make 4 different two into 1 logs, into an unorthodox 180° header (sorta) for a whipple charged, LQ9 in a sas, 4x4 Colorado! Anyway, thanks again, good stuff!!

[@metalman065]

I'm gonna put this out there and ask a stupid question,,. I've seen videos of guys welding aluminum with a mig welder and no spool gun.. using 100 percent argon, upsizing aluminum wire to .035 5356 and a .035 tip, and loosening up the drive wheel, My Question is, How good of a weld is this going to provide and will it hold? I know this doesn't pertain to this particular video, but I wanted to ask a professional and get a stupid question answered if possible... Thanks

[@davidduff9871]

Awesome. Very cool.

[@666MadDog]

could you please show how you would fit round ss tube to a oval shaped exhaust port? I have a gasket matches header flange and im trying to make it fit but i am missing a good idea how to make an easy jig to make it fit ;)

[@cromagnon305]

How it's made tfs edition. You can narrate with puns like "this was an EXHAUSTING day of work" haw haw

[@lynchingacers]

THATS SUPER COOL I ALWAYS WONDERED

[@FlyinRaptorJesus]

Dont they back purge when theyre welding these?

[@Mrsvetsare]

Realy coool homemade press tolls

[@projectinlinesix]

This was awesome! Thank you!

[@177SCmaro]

These guys can do in a matter of minutes what it take me all day to do.

[@craigfiles7067]

That was great more please

[@Kindo86]

You should take a look at the way “Burns Stainless” does their merge collectors, now those things are awesome....good insight with this vid tho 👍🏽

[@mikedesilets3324]

Just making me drool over all those tools.

[@stephenvale2624]

Seriously cool!

[@mainstreamgamer1300]

Whether in welding fabrication part require wps,pqtr,pgr before making the part?

[@Dutcharmytent]

I did a video on how to make a two into one exhaust for a Honda Bros Motorcycle with just an angle grinder and arc welder

[@samuelreyes7240]

Great video can't wait for more all ways learn something new here thanks. One more thing what song did you use

[@glennodfx]

How about proper 4:1 merge collectors?

[@weldmachine]

It was definitely good to see this. Thanks for the effort you put in, for us to watch. The only downside is could you imagine having to do this as a job Every day ???? Thanks again great channel.

[@normhowes2975]

I would like to learn how they weld the inner portion of the headers where the 4 tubes connect.

[@JG-kv4oi]

They weld the star where the four tubes meet and the bit of 4 seams up the sides, then slip the collector over the 4 and weld around the outside.

[@gasfiltered]

@@JG-kv4oi exactly right. Some people even go so far as to only leave the star and scallop the tubes so that there is what looks like a spike left in the middle. That middle portion is smoothed and formed so there's less turbulence at the end of the tube. There's so much power to be gained and lost in the last 8" of pipe.

[@JG-kv4oi]

@@gasfiltered Yes, I often weld a bullet shaped peice of tube in the center over the star to create a smoother transition into the collecter when I build a header on a job that warrants it.

[@normhowes2975]

Thanks JG and gasfiltered. I now understand the order of steps. I did know the last 8 inches to be important with the way the pulses enter and leave can make or break the power band.

[@aldetitman97]

Very informative thanks

[@mikemakuh5319]

Ever thought of getting an extra tig machine?

[@bps.1]

I had question about tig welder what you be a good budget friendly Tig welder

[@hi_is_this_clorox_bleach]

amazing video thank you

[@Six_ftdeep32]

I'd like to know what kind of bandsaw that is.

[@colinstanley4676]

Does anyone know what the general degree of bend one would use to make a 2-1 like that?

[@corbandallas8644]

Epic video! Thanks!

[@julianomenegalle1713]

Amazing vídeo!

[@skaterdudd]

hell yeah my brain is racing with ideas now