Weld Repairs You Should Avoid

[@TheFabricatorSeries]

HEADS UP! We know about the fake YT accounts saying you won. They are FAKE accounts. You will NEVER win anything from a comment. We will NEVER ask you for personal info, money, or additional details. The fake accounts do not have the official YT check mark next to them. They are just trying to get money from you. Click on their account and report it. -Justin

[@TheFabricatorSeries]

Additionally, we will never ask you to click a link, call a number, download an app, buy gift cards, trade them for bitcoin, fear that we are some random government agency with Indian or Nigerian accents, or ANYTHING related. Scammers are desperate, lonely, useless 3rd worlders searching for gullible people. Give them the biggest middle finger from America that you got!

[@danielsplayhouse3804]

@@TheFabricatorSeries lol 😂😂😂😂 that's too funny I had one say I won the whole welder wish setup I said I be waiting for you to call 🤙. LoL 🤣🤣🤣

[@PoBoysDiesel]

@TheFabricatorSeries Blessings from FL Justin here is one to report if it helps they messaged me @ TheFabricationSeries­4

[@danielsplayhouse3804]

@@PoBoysDiesel that's crazy they messaged me @Thefabricationseries 1

[@VikingRul3s]

I must say, I'm surprised you haven't invested some of those tube money, in one of those handheld "laser metal analyser" (don't know if they are still laser or developed). For those sometimes rare alloy mixtures in specialist products, like the veteran parts you handled here, that tool is quiet valuable 😉

[@capcloud]

Hey Justin, I just want to say you don't really owe us followers for sticking around. The amount of knowledge you contribute in the public domain is worth it's weight in gold. Thanks for being so generous with your time. I wish you surpass your goals.

[@MemorialRifleRange]

The pins and the flange are for cabin heat, there is a shroud that covers it and air is forced over the surface and pins as a heat exchanger.

[@Failure_Is_An_Option]

Thanks captain obvious.

[@Lonewadi6242]

@MemorialRR, that's interesting. Thank you for sharing.

[@MemorialRifleRange]

@@Lonewadi6242 You are very welcome.

[@EddSjo]

@@Failure_Is_An_Option Shut up, it was not obvious at all, you dink.

[@X19-x5f]

Good info. Thanks.

[@dougcarroll2043]

Hi Mr. Justin, thank you for the video. I play with airplanes and the original exhaust was steel in the 1930/1940 but as soon as they went to stainless steel, they started using a 321 stainless which intern uses a 347 filler. The 321 is cladded with titanium to help with the heat cycling, but I agree with you once the part is 70 years old. It has earned retirement.

[@PaulFalder-g7b]

I am a novice (hobby) welder from the UK and I find these videos so informative - thanks.

[@Mtlmshr]

I have done many of those same repairs, I make my customers aware of all the things you mentioned and leave it up to them and nine times out of ten they will ask me to do the work. Honesty is the best policy!

[@darrellmellott6096]

I was a welder in another life, but finished my career as a welding inspector in the petro-chemical industry. We often have to weld new material to existing material that has been contaminated by process fluids. While meticulous cleaning of the old material is helpful, there are often contaminants within the grain structure. A technique referred to as "buttering" is a useful in welding a difficult joint that has the puddle popping up with contaminants. This includes laying down a sacrificial pass or two of weld metal that is then ground out before attempting to weld out the joint. The oxide scavengers in the welding consumable will often eliminate enough of the contamination to successfully complete (pass x-ray inspection) the joint. Don't know if that would have been any help with this job.

[@nighttailglizzy6339]

With the sacrificial weld, do you just tap it once or twice around the edges or how do you normally do that?

[@jasonyoung22]

I have over 20 years of dealing with jobs like this and worse taken by my employer. Great job showing true hard work with experience and the difficulties that come with these types of jobs. Making sure the customer knows the very high possibility of a failed outcome is very important. Great video dude! Don't take the bad ones😂

[@codys_fab]

I do a lot of repairs on similar exhaust pipes for aircraft and I use the nonwoven rust/paint removal roloc wheels in two inch. They work great to get to that shiny weldable goodness without removing any material

[@geekswithfeet9137]

This is a perfect use case for laser cleaning. It’s definitely affordable at the shop level now.

[@clukait]

Yep, great stuff from 3M. I use them since I got to repair / weld some exause pipes on my and some friends motobikes. And Justin, thx for sharing your knowledge with us. I mostly taught myself TIG welding, read a lot and ultimately learned a lot from people like you. For all other types of welding I had lessons in my training as a car mechanic here in Germany. But that was more than 30 years ago.😂

[@donaldoehl7690]

Don't use brake cleaners for weld preparation. Look it up.

[@ryanmacewen511]

FYI! I have the right angle M12. It's only, ok. Does what yours does, but much less so. Point of post, I discovered the RYOBI pistol grip die grinder, and it is awesome. Lots speed, and torque. No stalls! I got mine on sale for $99 bucks with 2 batteries. I love it!!! I think it was as much as $179 bare tool. I'd say it's worth it, even at that price. I really have no brand loyalty any more. This RYOBI is actually very very nice. Comfortable in hand, and lots of power. I will buy another for sure. I haven't tried the M12 straight die grinder yet.

[@chowclelie9402]

Hi Justin， just wanna show my respect，you are a great person to show us free welding lessons. I really like your expertise and your spirit. I cant imagin how hard it is to work in such a hot place. Take care of your throat!🥤

[@ttargetss]

Justin I took your stainless and aluminum TIG courses four years ago and it was without question the best money I’ve ever spent. The various platforms you’ve created to help others learn are incredible. What ever happened to the car you were building?

[@billynomates920]

nowhere near vegas, never welded a thing in my life, no nothing about video but what you're doing is great!

[@smnkm4ehfer]

This makes me feel a lot better about my welds! Im a machinist jit a welder but i do 90% of the TIG jobs at work(ive been TIG welding for years unprofessionally) but we usually get dirty, old, irreplacable parts for old equipment, and if YOU can't make every weld look like a banger, i feel good about my welds on similarly fugged parts not looking like IG welders lol. So far knock on wood nothing has come back. Thanks for the content

[@BruceLyeg]

I used to subscribe to a LOT of welding and fabrication channels, now I follow maybe four or five and you are by far the best one. You have the natural ability to be able to make learning as interesting as it is educational. You're a great instructor / teacher, and a fantastic welder/fabricator. Thanks

[@gravely1000]

As already stated, your skillz are top shelf! I was watching that forward back and thinking wow, then you commented on it to confirm what I was seeing. I doubt I'll ever attend a class or do welding for money but I definitely want to thank you for posting up these type vids for us hacks out here melting metal and trying to claim it as welding. Keep up the great work!

[@Sparrowash97]

I recently started a welding/fab job with a heritage steam train company here in the UK. So I can totally relate to the frustrations of working on 70+ year old parts that have had countless heat cycles through them, most everything is also covered in grease and soot haha

[@IscuAndrei]

The glow is caused by higher content of chromium and a few other metals that are used in aviation stainless. That's quite the nasty stuff and I wouldn't go near it without a respirator. So people should really appreciate the fact that you do all this just to teach us! Love to see you work.

[@notanymore9471]

“Aviation” stainless? What grade is that? 😂 is it like aircraft aluminum? Literally no such thing. 😅

[@Yan1nc]

I came from the 7 years old intercooler piping building video, honestly inspire me to make something way better on my DSM

[@aarondiller8394]

When you mentioned the smell of avgas, I figured lead would be a potential hazard. Your instinct to wear a respirator was a good one. Thanks for a very informative video!

[@Fix_It_Again_Tony]

I will take the reduced audio quality so he can wear a respirator and protect his health.

[@PoBoysDiesel]

Blessings from Kissimmee FL brother I am sorry about the fumes and the reaction on your throat I had experienced something like that years ago when melting lead I hope you feel better soon Take care bud

[@darrellmellott6096]

A few comments from people familiar with aircraft parts suggested this exhaust may have been Inconel not 304, 310, 316, or some other austenitic SS material. If you are convinced that an unknow material is stainless steel, but unsure of the grade, a good option for the consumable is ENiCrMo-3. It will work as well or better than E309 on 300 grade SS material and definitely better if it happens to be Inconel. The only cavate is that it is expensive.

[@jaimeb4774]

Much love from So Cal, appreciate you for this walkthrough and countless others. I've been tuned in since your tube bending series and can't tell you how much i've learned from your channel alone. As for this video, thank you for sticking through the +100 degree weather, getting the raspy voice, and still being a good sport about it. Take care!

[@wesbri-p9e]

This angle die grinder is designed for high speed low force. I've had good success with 3 in Scotch-Brite Roloc. Assuming your wire will is designed for a drill, the max rating is 4500 RPMs. I noticed you had it on the the the highest setting, which I believe is over 20,000 RPMs. It's also kind of dangerous. Hate to be the safety nerd.

[@HexyTech]

@@wesbri-p9e yeah, I've exploded a couple of wire wheels with my die grinder - they definitely don't like 20k rpm! Still finding bristles around the shop months later 😆

[@TradeWorks_Construction]

35:00 I don’t know if many noticed this but the tungsten tip to work distance was incredible. The control he demonstrated after the arc did its wandering after startup was insane, unlike in a straight line keeping that tungsten soo close across the uneven radius corner takes incredible skill and concentration to not dip the tungsten. The fact that he did dip the tungsten before the shot goes to show just how difficult and uncooperative this piece was being. Porosity aside most people would struggle with the skill to even replicate the result so YES your intention to pick and choose your jobs, refuse the jobs that demonstrate potential issues got across … (at least it did for me).

[@davemcdaniel4856]

Sr George Utah here, My neighbor might have got your McDonalds, we were talking and here comes the delivery guy. Def didnt order it, but his name is Justin too! I made a WMO order to make up for it. Id also love to win the welders, my everlast are ok, but those would be better. ;) Your smelling avgas, and its 70 years old, its probably actually lead that has built up and then melted into everything. Lead starts offgassing toxic fumes around 800°f. Lead is clumpy and sludgy and doesnt like to flow out.

[@danielsplayhouse3804]

@@davemcdaniel4856 I've mentioned the same thing I do repair on a lot of aircraft exhaust for experimental airplanes no certificates needed for experimental airplanes but have to be careful about lead gas it's even in the av gas low lead still gases off have a hi Dollar respirator for it. Even had it when doing flooring for 20 yrs allot of old floors containing asbestos and formaldehyde....

[@Rollin8.0]

That was my thought also when he mentioned the funny glow... Highly likely to be lead 🤮 hope he didn't have to breathe much in!

[@AkPacerPilot]

That ring around the aircraft exhaust is for the cabin heater and the carb heater. It’s a shroud that goes around it, the nubs are to help transfer the heat to air, airflow comes from the prop airflow / movement thru the air.

[@francisrampen9099]

I suspect it is virtually impossible to truly clean lead off of a piece of pipe as you tried .- lead is forever. Nice to see when even a professional struggles - it gives me hope that my technique will improve.

[@donaldoehl7690]

Don't use brake cleaner because it makes phosgene gas when you weld. VERY unhealthy. There is a vid from welder that suffered liver damage this way. He may have passed already.

[@transmitterguy478]

Great job Justin! Now I know what to expect on a heat-cycled piece. Thanks

[@the_bishop]

Hey, Justin! I can't thank you enough for these videos. I've learned so much from them.

[@tasteywheat1332]

That weird smell may actually be lead contamination as aircraft can run "Avgas" which still contains lead to up the octane. I have welded an exhaust off a plane that has run Avgas before and it is a very distinct smell along with the white fume that looks almost like an incense burner.

[@captaintoyota3171]

Yup lead 4 sure, specially being a 1940s/50s era exhaust

[@silaskuemmerle2505]

Not only CAN they run AvGas, they are required to use AvGas unless the owner spends a lot of money to get an STC to run MoGas.

[@silaskuemmerle2505]

@@captaintoyota3171aircraft still burn leaded fuel

[@ulbuilder]

Lead makes a blue-white color when burning so I would say that confirms lead is the issue. Dont want to breath those fumes!

[@EShirako]

I was actually just making a comment to mention that, glad I looked first. :D Yeah, and I wonder what the residue on the inside of the melted metal. What does stainless become when glazed with tetra-ethyl lead and soot on the inside?

[@KZ-yy9pm]

Still don’t understand how this channel doesn’t have millions of subs.

[@philipmendorensis8687]

Because not everyone is welder? and every welder don't spend lot of time in yt I guess?

[@KZ-yy9pm]

@@philipmendorensis8687 There are a good amount of “fabrication” channels with more subs.(I get subs don’t equal views) Something to think about, is everyone that watches “Deadliest Catch” a crab fisherman? Does everyone that watches “Dirty Jobs” clean sludge out of sewers? Watch “B is for Build” he basically talks while an hourly employee does all the work inbetween blatant 20 minute advertisements. I don’t mean to bash that channel too much but it’s kinda a hack operation. Have you seen the latest underwater art display they are building? There is also that other channel where it’s all jump cuts with bad generic rock/metal music playing while they butcher everything they do.

[@baronburgamot243]

​@@philipmendorensis8687 Erm... This Old Tony, Welding Tips and Tricks, AvE, all over 1M subs.... Honestly Justin doesn't get enough love his content is fantastic.

[@emilevenrud]

the angled grinder is only ment for 2 inch attachments, tried 3 inch myself and it doesnt work, atleast not with wire brushes, a lighter sander might work, but stick with 2 inch stuff and it will work nice. ( had mine for over 4 years now.)

[@jollykreiger9938]

2nd that

[@davidhaas2528]

YEP!

[@WebWheeler]

Yeah I've gotten away with 3" paint stripper discs since they're lighter weight and less drag but 3" wire wheels have too much drag. Mine has been abused for 3 years and still works great

[@Therealabedjoud]

I think it also has to be centered. I had a 2 inch flap disk and it was just slightly off, and it kept stopping as well

[@turboflush]

Yah it has an overload cut out. The cutoff wheel does the same thing.

[@jamesguzmanii9812]

Glad you're able to be back. The way you break down what you're doing in the videos is enjoyable to watch. As much welding as I do teach, I wish I had all the skills needed to come work with you. Maybe one day.

[@bwcordes]

I'm thrilled with the announcements at the end of the video. Congrats on your success, and best of luck in the future. I was speaking with some of the guys at the annual Shelby Dodge convention this year, and not surprisingly, we all watch your videos. Keep them coming.

[@genedavis9819]

Thank you for letting me watch you weld. Your talking as you weld helps a lot. If my view through my helmet was as good as your video I could be a better welder. Keep up the good work. Gene

[@sizzle073]

Hey high speed, drink some buttermilk and honey to soothe your throat. I’ve been watching your videos for a couple or three years, and I enjoy watching your high enthusiastic and professional approach to welding and fabrication. No I’m not asking for an instructor position, I know I’m not one your looking for so I’m not trying to butter you up. I just wanted to let you know I’m impressed with your willingness to share your tips and the strive to make name for yourself with the skills you have. Keep it up, and don’t forget to take a break once in a while so you don’t burn yourself out. Best of luck Justin!!

[@ypaulbrown]

Justin, your enthusiasm is contagious, I have never seen you this pumped up before......... congratulations on your growth and plans for the future........PB

[@robertkrauss7161]

It is also possible the part is inconel as it’s a commonly used alloy for aircraft exhaust

[@silaskuemmerle2505]

I have never heard of an inconel exhaust on a piston engine. Turbines absolutely, but not pistons.

[@Awkward_Fox]

​@@silaskuemmerle2505 In the World Rally Championship, Inconel is used in a few high heat areas on the car. On the old Subaru WRX cars, it was used in part of the exhaust as part of the anti-lag system. It wouldn't surprise me if the manifold is Inconel because of the use on an aircraft

[@silaskuemmerle2505]

@@Awkward_Fox well that's an aircraft part not a car part, and as an aircraft mechanic I have not encountered an inconel exhaust on piston engine aircraft.

[@christopherprisco8690]

Has that sludgy look

[@heyitsjel]

Agreed; or even possibly Monel... could explain the weird oxidized colour, and also why the weld pool was acting a little different...

[@motionsick]

Glad to see the double OG is still posting.

[@allensketchclub8579]

first and foremost, thank you for sharing your expertise with us. you are a wealth of knowledge, and i know that many people have learned so much from you. (especially how to load a trailer,....) i am excited to see more fabrication content, and the news about more forthcoming is quite welcomed!! i am equally excited to hear of the plans for a specialized technical program in the works, and hope for outstanding success with that. i also hope that you can find the right people for the work. i believe that will just catapult your endeavors to the moon and beyond. all the best and keep well.

[@TheFabricatorSeries]

I swear I'm never going to live out the trailer loading comments despite my success 6 times over 😅 Thank you for your comment and continued support! -Justin

[@ridinrocks]

I think we all can tell your a bit overwhelmed with all of it just keep it going happy too see your making it all happen congratulations

[@galenanderson6006]

I bought a Milwaukee rotary tool. The first one died after a couple uses. It was "repaired" once (they didn't return the collet nut) and then replaced under warranty after it failed again. On this one, any signifcant load and it quits, but will restart after a few seconds. I still rely on the corded Dremel for extended use.

[@BurnerJones]

All of them do that. Any real load and it turns off after a second or two. Worst tool I've bought from them by far.

[@will.5642]

I have a straight grinder bosch ggs 18v 10slc hasnt let me down yet. But its not light and not really a one hand machine.

[@ShieldArc200]

You are overloading the small 2ah battery. Try a 4ah battery.

[@michaelkulaga7512]

The stud setup is for the cabin heating, on a lot/most small airplanes they heat the cabin using exhaust heat, pulling air through a shroud around the manifold, the studs help with heat transfer.

[@099bmac]

hey Justin, If it was going on aircraft It's SOP to back gas otherwise you will get embrittlment (sugar baby). I wold use a 347 rod .035" or .045" on this, most AC exhaust is around .060" unless it's on a turbo which is usually a little heavier. I really enjoy your video's, Thanks!

[@rayfalcon777]

Great video however from one welder to another one i can honestly say as welders we know our limits thats why we let another welder maybe with better equipment, better skills ect to do the job(s) that we cant or wont do however never ever have i once whined or whimpered or cried this bad lol jeeze so its welding like trash strip it down clean it extremely good polish the stainless after the initial prep, then use argon and nitrogen to flash the piece before welding, allow it to then vent and do a final polish fill with argon and then weld it wit 403 or 440 filler and a fresh tip

[@toddjuneau4702]

First time watching your channel & video. I was very impressed with your determination to fix this problem & you almost overcame it. True that the metal is oxidized or has so many little pin holes in it thats what the problem surely was. Sure, sandblasting may have a been a part of it but after 28 years in this industry I would still lean back on severe oxidation & fatigue of the metal. I would've either welded it out, tiger paw or grind out any porosity, welded up those spots then "tiger paw" or flapper sanded the whole weld putting down a light stringer then examining the weld for any defects, if none, sand it down yet again, clean it well with a solvent then go for the "full monty". My second choice would be to cut it off nearest to the base metal & ship the piece off to a company that could replicate the piece, get it back into my shop & weld it back onto the original piece. Sure, its more costly but your dealing with aviation parts that help or make the engine run. Thats not the exhaust of your buddies side by side or a 4 wheeler. Good video & I know your cooking hot in Nevada at a dry heat of 115. Try doing what your doing in deep south Louisiana at 11 0 with the heat index at nearly 100%!!!! Good luck brother & keep on doing what your doing!

[@brolls2735]

Most the moisture your seeing during pre heat on the metal is a biproduct of the torch combustion. Its condensing on the cool metal stops once it heats up.

[@evanchi9460]

This. It drives me nuts when people insist that they're magically drawing moisture out of the material. It is simple condensation from the biproduct of combustion of many hydrocarbons, water...

[@Zerk_Ziegler]

The same thing happens when hot air from an electric heat gun hits cold metal. Moisture in the hot air momentarily condenses out on the metal and then quickly evaporates as the metal heats up. Car windshields fog up through an identical mechanism.

[@davidg3944]

@@Zerk_Ziegler I presume you're responding to a spambot that said you won something? That message has been removed.

[@Zerk_Ziegler]

@@davidg3944 👍

[@buxybuilt1519]

That’s a 90 degree die grinder you got there Justin. High speed low torque. It’s for die grinding haha not for chucking a huge wire wheel on. Thats some awesome news, I’m happy it’s coming together for ya!

[@JFirn86Q]

Amazing camera work, as always! Great episode. Can't use those big attachments on the mini right angle grinder, it overloads it for me. Works great for using smaller attachments where you don't want a big angle grinder. Also works really great for cutoff wheels (it can handle larger ones of those).

[@boblow2186]

Q douse to you sir. For what you’re doing hope you get the right people to help you going forward. Look forward to seeing what you have to offer. All the best 👍 Bob.

[@aaronmurakami1120]

So glad to see TFS back up againb and understand hat it had to take a hit for you to get weldcoach up and runnin. Honestly watching TFS is what inspired me to get into metal fabrication so I am going back to school at 46 to start over. RTeached the top of my last career and was not rewarding anymore so on to the next chapter just waiting to hear back about a fgrant to go back to school since it is something that is offered in the area I live and the tool grant will hjelp iommensly especially with purchasing an AC/DC tig machine for myself along with a plasma cutter

[@ypaulbrown]

Dear Justin, still here and always a fan of you and the Channel.....best regards from Orlando, Paul

[@brianconnell6587]

YESSSSS! More classes! Cant wait, thanks for what you do!

[@casey360360]

Dream job right there, would definitely be able to jump in and take control of the role, HELLA not in the right spot in life to come and join TFS. Not even remotely close. I'll stick with wrenching for Tesla for now.

[@thekeitohappiness]

Im a huge advocate for those milwaukee die grinder you have there. Been using them for a long time. Pick yourself up some 2" "Roll Lock" discs and a 2" arbor. I personally really love using the scotchbrite versions, you can get way more aggressive with a flappy wheel style Roll Lock. They're great tools budd! Asking the wrong thing from it - by putting a 4-5" wire wheel and jamming it into the piece. Please order this up, and give us a review in a following video! Thanks again! Love from Canada.

[@WojnarskiWeldingFabricaion]

I have both Milwaukee grinders too at work and a set for home. I have a love hate relationship with them. They are kinda limited to 2” attachments. I use the straight one mostly for carbide burrs and the right angle one with a roloc attachment and a 2”-3” flap disc. And other attachments works good for quick deburring of a saw cut or paint stripping. Wish they made a little higher power set. Good video 👍👍

[@EOTG_AK]

The M12 right angle grinders have some kind of load shutoff. They do great if you can keep them at high rpm and have a light touch. They work great with roloc flap and bristle disks. The big batteries are pretty much required to do any real work with them but I’m sold on them! If you don’t have the M12 Cutoff tool then you are definitely missing out! It fits into much tighter areas than a grinder and being able to reverse the blade direction is awesome for keeping sparks out of your face (or anywhere else you want to keep them away from)

[@cesarortega6615]

I won't be your first student but definitely one. I've always wanted to learn that for automotive racing purposes. Currently debating if to purchase a mig welder to do the famous E46 chasis reinforcement repair

[@neosenshi]

I have the same grinders: like other commenters have said, they work great with smaller wire brushes, but struggle with too much load. I use mine for the scotchbrite disks.

[@alekseyshevchenko3565]

I just realized I bought a tig torch for my Everlast from you guys 😂 and that grinder needs a higher amp hour battery to not stop like that , I have both of those Milwaukee grinders

[@dbayboyds409]

Great video. I’m sure you’ve saved some novice welders a lot of time and money with the experience you’ve shared!

[@ERusstbucket]

As an aircraft mechanic, I clicked as soon as i saw the aircraft exhaust. This video shows very well the reasons most aircraft exhaust repair stations end up replacing all but one or two flanges with new metal. Reusing just a few components makes it still considered a repair instead of a new part despite almost all of the original material being replaced, similar to the ship of Theseus.

[@AgentWest]

Are you not allowed to braze aircraft exhaust? Are operating temps just too high for it to hold? Also, what are those pegs sticking out of that one header in the video?

[@ERusstbucket]

@AgentWest even a low power carbureted aircraft engine can have exhaust temperatures above 1400°F for several hours during cruise; that's way too hot for brazing. Those pegs are to transfer heat from the exhaust pipe to the air outside the pipe. As others have mentioned, there's a shroud that covers the exhaust, which lets either engine intake air (preventing carburetor ice) or cabin air be heated using the exhaust pipe as a heat exchanger. If you want to see it look up "cabin heat shroud" or "carb heat shroud" in an image search.

[@ERusstbucket]

@AgentWest even a low power carbureted aircraft engine can have exhaust temperatures above 1400°F for several hours during cruise; that's way too hot for brazing. Those pegs are to transfer heat from the pipe to the air being ducted to either the cabin or the carburetor for keeping the pilot warm or the carb from icing.

[@AgentWest]

@@ERusstbucket Curious that it would use exhaust heat for cabin heater, but makes sense for air cooled engines. Also I did not realize just how hot aircraft headers get.

[@ERusstbucket]

@AgentWest that is one annoying feature of air cooled engines. To save weight the exhaust is thin walled, so they are prone to cracking too. Carbon monoxide is a very real danger for pilots and still gets experienced pilots. AOPA has a great interview with Dan Bass, who survived after he passed out and his plane crashed into a field.

[@dusthill7032]

Been missing this guy for awhile

[@mikesalm5053]

I'd probably be one of the first to sign up for the school. I've done a decent amount of fab work and welding over the years for myself and my friends, but would love to learn as much as possible

[@robhunter2435]

You handled that job like a champ

[@daniel635biturbo]

Very interesting video ! Those struggles are real, I've been there several times. Sometimes, in Aluminium, I've just added filler, ground it down, and more filler again and again. In a sandblasted non aluminium part, I'd probably recommend stick welding, as it's less sensitive. In this case, with so thin stainless, stick welding is probably not an option though. So just keep on struggling with the TIG it is 😅

[@samscott5230]

As an aircraft mechanic and hobbyist welder who has tried these repairs, I thought I just sucked at welding. Glad it’s not just me. I know better than to attempt these repairs now.

[@johnstubbe3113]

A great way to get a cheap Forced air hood is to get a mattress inflator that’s battery powered and then you put lithium batteries in it or regular old batteries doesn’t matter .A flex hose ,add a filter and a nice piece of very flexible inch diameter hose to go into your helmet and you’ve got it without spending 1500 or two grand . You might need to slow air air down with a Rio stat or lower voltage . They blow very large CFM in stock form.

[@baronburgamot243]

Too much drag on the 3" wire wheel. They don't have loads of torque. Be alright with a 3" roloc and a 120 grit or something. Wire wheels have a lot of drag. I've stalled out my 1200watt dewalt corded grinder by pushing it in to much with a knot wheel haha. Another great vid Justin! Keep up the good work

[@AndrewReiwitch-sw9lf]

Justin, Milwaukee likely has an auto shutoff on that tool due to the circumference of the wheel on it, causing the auto-torque reaction simulating the motor was stalled due to being captured or stuck... To save the motor. Try a smaller wheel... Awesome content, as usual!!!!

[@joesharp5602]

As always Justin, a great video on a great channel. I am an old dog and yet you teach me new tricks with each video. With great respect.... Joe

[@Preen59]

Man great work. The videos you have produced are fantastic, I've learnt a lot over the years from watching them. Congratulations. Keep it up.

[@joshrob316]

Hit the power level button on the back. You're killing me dude

[@daniellucas7715]

Challenging jobs like this make us better welders. Even if there is a 100% chance of failure. Even if you don’t get paid for this job, it’s still a great learning experience. Remember, experience is priceless.

[@jrl8282]

What a great teacher. Someone that enjoys what they do and shows the rite way to do it is priceless. Thank you for another great tutorial :-}

[@ryanjohnson9325]

I use that M12 Right Angle alot of hours a week and with 3" Discs it is very annoying. But you have to understand the limitations of the tool. 2" Discs are no issue and that little grinder will put in work!

[@tools6106]

I do a lot of repair work, hydraulic oil lines and oil pressure lines. Typical is .045- .065 material aluminum and stainless steel. .030 filler is typically the choice to not over heat the base metal. My system is to add 5 amps to the base measurement so .045 base metal plus 5 amps gives 50 amps top setting. I start out beyond the crack or hole and slowly work toward the actual fracture. I grind out the crap and revels till it flows clean. Usually it takes 10-15 passes of regrind and reweld. Never on a few passes alone. The reason people call me is no one else will touch it. 10 hours is not uncommon. But on rare occasions people know there isn’t a part available in the known world!

[@campbellpaul]

I'm gonna have to get me that Milwaukee tool... It looks like such a tried and true success!

[@neatoelectro3687]

I'm super excited to see TFS coming back into your focus! Super excited to see what you cook up! I'm sure it'll be spicy! :D

[@Turbos4Lyfe]

I have both of those Milwaukee 1/4 grinders as well. I run the 5ah batteries on them and they just do that with big wheels. 1.5" wire wheel works best from what I've done so far. Or a sanding disc

[@StevenJevnisek]

Hi Justin: Thank you so much for your great instructional videos! I would love to work with you at some point, when I get my small boat fabrication business up and running. With regard the the Milwaukee M-12 tool... I prefer Milwaukee and Dewalt. I have several of both. The only Milwauker tool I was dissapointed in is my M-18 hammer drill. It only drilled 7 holes before failing. On the other hand, my M-18 drill, 1/4" hex tool driver, grease gun, and 4.5" grinder work great, (though the grinder goes through batteries quickly.) As for the repair jobs you showed, I thank the person providing the examples of what to reject. The customer would be much better off having you fabricate a new exhaust system from scratch than having you waste your vauable time, (with the 3xception of this valuable learning opportunity,) trying to save a dime at the expense of humdreds of dollars. Keep up the good work!

[@Kneedeepingore]

The rightangle diegrinder works best with rolocdiscs, wirebrush is a no-go, use a drill for wirebrush 😅 The worst repairs i know of is the people that say they haven't tried anything, then comes in with a aluminiumpiece covered in JB weld

[@TCreatorO]

Man it was hilarious watching you go through my same experience with the milwaukee diegrinder, I later read the manual, and the wheel we were using is too big, try to only use wheels under 2" if I remember correctly, then it would only cut out under heavy loads, otherwise it will work just fine, and no, it will not replace your air tools, I had the same dream, but electric tools dont cut it

[@airmotivewelding8012]

Super job, very typical of used up aviation exhaust. Good amount of LEAD contamination, heat cycles and the parts are THIN. Operational cycles also thins the wall of the tubing due to erosion. I do this kind of repair frequently. Challenging to do and be airworthy.

[@charleslesther3043]

Re: editor/photog Ideally you can find someone who can build out some infrastructure too. Permanent lighting setups for a couple different spots in the shop, robust and efficient storage system, etc. That kind of efficiency stuff is EASILY worth another entire person in terms of speed/ease of production. [I have 20yr in various audio/video/live jobs in TV/production/broadcast ops] Good luck!

[@jsuninyoureyes]

It's not a grinder it's not made for wheels. It's made for die grind bits.

[@panther105]

After working on many old planes, even WWII birds, the availability of refurbished, and new exhaust systems is minimal. If you can become good enough to get certified to do these thin metal repairs....you will be a God..!!

[@Jason9ll]

FYI for those grinders you really need to use the high output batteries. They make a huge difference. I've been using them for a couple years now at my job

[@Nord3202]

We get all our plane exhaust parts fabricated from new metal. Two companies Plane Exhaust & AWI fabricate those old plane exhaust pipes and mufflers from scratch.

[@richardparker937]

I worked a contract job for a 150 year old candy co . To do big repairs . Everything was steam heated . Stainless just disappeared when welded , no place to clean inside of parts , oh joy , the cast iron was just the same ! One part I totally remade out of copper pipe ! I’m retired now , but miss the problems at hand

[@StephenKirker]

Great content! And 2 wonderful gigs. I wish I could...

[@coreyl1501]

Thank you for covering this topic Justin.

[@ganzeytyler]

Those grinders are actually amazing, but with a max diameter of 2" wheels, 4" for cutting wheels. the ryobi version works better for larger wheels because it only cuts out when temp gets too high vs the Milwaukee that goes off of load.

[@p52893]

If it’s not going back in the plane I would recommend pure nickel filler rod or silicon bronze

[@danielsplayhouse3804]

That second one I would have passed totally do to lead in the pipe I was just thinking about that airplane use lead in the fuel. Now they use low lead av gas ! Should have had a respiratory on.. 😮 good job Justin I have been leaning towards remanufacturing old airplane parts like that since I live in-between two airports srq & St. Pete keep up the great content Justin you do it all the time bud!

[@bobcote1375]

Not an easy weld job. I always struggle with them. I think the exhaust gasses contaminate that metal so much that what ever you do to prep isn’t enough. Great job toughing this one out.

[@Lee_In_AZ]

I have the M12 RA die grinder and it works great with 1”-3” roloc discs. I do use a 5ah or 6ah battery with it though.

[@blueberrychronic]

You gotta try the electrochemical oxidation removal process that they use on stainless and titanium exhausts next time. Should help a lot next time!

[@Sub211Weldz]

Every welder "ill try not to burn my self, that's a little freaken hot" 😂 love the vids keep them coming