CME on Saab 9-7x Aero - First Time Welding

[Dirty 30]

I posted this on the TBSS forum so figured I share on here too .....

So I've been wanting to do a custom center mount exhaust setup on my Saab like I had on my old Envoy. Instead of spending $500 to get it done, I decided to buy a MIG welder, a miter saw, and some tubing to do it my self. I have never welded before so I read a book, read the owners manual, and started to make a couple of practice welds with two small 3" tubes. I am going to install my Pacesetter long tube headers and Y-pipe at the same time with the CME. I dropped off the headers at Enduro Coatings in Mesquite, TX to get them ceramic coated. Just wanted to share some pics/info as I work on this project...







The rear bumper cover already has a nice valance with a cut-out for the hitch receiver. I'm just going to have a body shop fill in/smooth out the cut-out for the stock muffler tip and the trailer wiring harness. While I'm at it, I want to get all the lower rocker panels paint matched.



First I took the rear bumper off and cut the center of the hitch receiver out. I didn't want to cut all of it out since there are some small brackets welded to the hitch for the bumper cover. This piece weighs 15 lbs...



For my first welds, I welded some flat plates to the open support bracket so it wont look too ugly from the outside. I didn't have anything to cut them with at the time so i just welded them on as is. I still have to cut off the trim areas and smooth the edges out. Also gonna spray some rustoleum on the bumper once I'm done...

[Dirty 30]

I found some exhaust flanges at a local circle track parts shop and welded them to the headers. These flanges are the 5th and 6th welds I've made so far and I still think they look better than what most local muffler shops do






I used (2) 45 degree 3" mandrel bends to make a "y-pipe" for the exhaust tips since I will be using a 3" single inlet/outlet magnaflow muffler (which is already installed on my Saab). Wasn't easy and didn't come out pretty but will work fine...

[Dirty 30]

I cut the trim on the plates for the support bar, smoothed it out some, and painted it black...





I held the tips on with a jack stand and took a pic of how they will look from the top...




Its a 120v Lincoln Electric WeldPak 140HD and a 75/25 Argon/CO2 gas mix. I used the .025" wire that came with the kit. I have to be honest, I was so nervous using the welder and the miter saw that I was sweating like a mofo. The miter saw isn't really meant for cutting steel but I put a cutoff disk on it and was well protected. Both will come in handy in the future tho. I bought them for myself on Christmas


More to come! My Saab is at Phoenix Transmissions in Weatherford, TX right now. They are borrowing it for the week to test fit a 4L80E with an adapter for AWD. Once I get it back I should have my headers by then and keep on working on it.

[toxicavenger]

Damn bro it is looking pretty good. And actually your welds don't look really that bad for being a newbie at it. It will take time to get a good flow to your beads, but you are on the right path! Good job.

['97 Saab SE Turbo]

In case you didn't know it, Lincoln Welders are made by Lincoln Electric in Cleveland Ohio, which has a great profit sharing program. In 2008, elegible employees averaged close to $29,000... Ron

http://www.istockanalyst.com/article...icleid/2877574

[Dirty 30]

Got my headers back from Enduro...

[timg]

I really have to get a welder one of these days...

Tim

[chiller]

Sweet. Can't wait to see the final product

[1BAD97X]

Unbelieveable!

[Dirty 30]

Got a new job early this month and have been going to school so I haven't had time to update with new pics. I finished the cat-back a few weeks ago but still haven't installed the headers. Here are some pics I took right now. I'll take some better ones this weekend. Sound on video kinda sucks.

[mikeb33]

Originally Posted by Dirty 30

My Saab is at Phoenix Transmissions in Weatherford, TX right now. They are borrowing it for the week to test fit a 4L80E with an adapter for AWD

Glad you are not selling it. Awesome exhaust work for an amateur.
What's the deal with the trans? What kind of adapter?

[Edmonton9-3]

As a Welder/Pipefitter, your welds make me cringe, they are probably just ridden with verosity.

On the other hand, for your first few welds, those are DAMN good for a beginner.

good job man

[Dirty 30]

Originally Posted by mikeb33

Glad you are not selling it. Awesome exhaust work for an amateur.
What's the deal with the trans? What kind of adapter?

It's a heavy duty 4-speed auto that normally come in GM delivery type trucks and 2500HD Silverado's and Van's. The adapter is to be able to fit that transmission with the AWD components in our trucks. No one else makes an adapter.

Its probably the strongest transmission from GM so far. Even a stock 4L80e can handle a lot more compared to a performance built transmission (4L60e/4L70e) that come in these SUV's.

[Dirty 30]

Originally Posted by Edmonton9-3

As a Welder/Pipefitter, your welds make me cringe, they are probably just ridden with verosity.

On the other hand, for your first few welds, those are DAMN good for a beginner.

good job man

Thanks! I need a lot more practice