Exhaust welding worksmanship

[Vertigo]

Sup. I decided to go with something smaller than my bigass free flowing 3in catback, and get a 2.5in custom made. My mechanic, Chris, saw the worksmanship of [certain exhaust shop], and recommended I see them and get it done there. I $&#$% up, thought he said... [another exhaust shop]. Wont name names yet. The first attempt they had, they forgot that I said I wanted dual tips until halfway through. They had plumbed two coby silencers in series, with a single tip out in the standard location for an AW11. When I reminded them it was meant to be dual tips (one on each side of the car), they decided that the best option was to just tap into the pipe between the two silencers - so most of the exhaust gas just went out that tip. I dont have pics of this one unfortunately.

It was $&#$% loud and obnoxious, and I took it back the next day telling them I want it done properly, with a muffler with two outputs. A week later I finally get the car back, and yea, it sounds pretty good. Got it up on a hoist at Chris's this morning, and the true story was told. Ill let the pics do the talking here.

http://imgur.com/BG4LmGH,FXrvk19,YVoxgq ... ,XM9prX9#0

Chris took one look and said take it back, itll fall apart. Cold welds everywhere. He was appalled, especially for what was now a bill of $1100. I quite agree. The exhaust sounds not bad, but wow, those bends... and the whole thing is slanted, which isnt the biggest concern in the world, except when you pay as much as I have. The tips are also not aligned properly. And the welds - I could weld like that, and I never have in my life.

Ive called them back and told them Im not happy with, well, anything except the sound. The guy sounded scared. If it doesnt get put right, Im asking for a full refund and going elsewhere.

[Stott69]

WTF! How the hell did they do the bends? Was this a seaside workshop with LOTS of seagulls roosting?

[Alex B]

Jesus

[Vertigo]

Its pretty shocking eh... I struggle to understand where my money has gone.

[GDII]

Did you actually hand over your money for this?

[Flannelman]

The standard of the weld is poor.

By the looks, the welder is inexperienced. (I do have a welding Cert, but class myself as a novice) So from my eye, the Volt setting is close to the correct setting IF the wire feed was less. However, because the user has been too slow in moving the puddle, has blown through. To combat this, wire feed has gone up producing the metal slugs.

Before my welding course, this is what I used to do.

The result of the crush bends is the very reason why i buy the 180 U bends and build my exhaust that way. Its more work, but the result is an even internal dimension.

As for the fix, I can't see any quick and easy way to repair. Grinding the welds and doing them again keeps the material, but that doesn't address the crushed bends.

Do NOT let the person who welded this do the work again. Not even to TACK it together!

I'm sorry I don't live in Auckland, as I would offer to fix this for you for the price of CO2 gas and wire used.

[Akane]

Holy shit that's shocking.
Sorry to hear that, $1100 for Cobys and tacked on ends is gonna be a hard pill to swallow.
I am in Howick if you want me to TIG up the thing.

[RS13]

I wouldn't even think an apprentice did that. I'd be embarrassed to let that leave my shop.

[Vertigo]

Should mention it was around $750 for the original 2x coby exhaust, and then about another $350 to redo "properly". So about $1100 all up. I wasnt happy spending another $350, but I figured it was worth it if it turned out perfect. Far from it, unfortunately.

[whynot]

Hmm i have done better with an arc welder and welding is not my trade.
I might suggest if you want a good job done on a difficult car to go an approach a welder fabricator. I did that with my ae92 and it's 3 inch stainless exhaust. The cost excluding mufflers was about what you have spent already and in my case he did an absolutely awesome job. They also have access to a better range of pipe and fittings and know how to use a welder properly.

[Vertigo]

Good tip, thanks!

[Bling]

This is so fitting...



That is beyond a joke! Good luck getting it resolved, f**k, just wow.

[Dell'Orto]

I struggle to understand where my money has gone.

MIG wire is expensive, they must have charged per metre
Terrible job though, clearly someone who has no idea how to weld at all!

[Akane]

You're better off with this, at least it won't leak

[Stu-]

Yep thats right up there with some of the worst Ive seen - they clearly had the apprentice on the job

[Vertigo]

AFAIK, it was actually the boss/supervisor/manager doing it. Staying late to finish, multiple days, too. I think he had never welded before, but cant prove that (lol, except with these pics).

[sergei]

AFAIK, it was actually the boss/supervisor/manager doing it. Staying late to finish, multiple days, too. I think he had never welded before, but cant prove that (lol, except with these pics).

I am not a welder, but my first weld was much better than that. It takes someone special to come up with that quality.

[Vertigo]

Ok, all joking aside though, a few questions:

What do you guys really think of the overall design? There is similar flow from each tip, so I assume the right hand pipe length doesnt matter so much. It sounds decent. I had something different in mind (a muffler with an output pipe on either side, for instance), but if it sounds good and doesnt hurt performance, Im happy.

Also, assuming it was well made and done professionally, what would you expect to pay? Just trying to get a handle of how much Ive spent vs what I should expect. This is my first exhaust.

Its back with them now - they have the right to attempt to address the problems before I ask for a refund. I pointed out exactly what I (and everyone else) had a problem with, and asked for mandrel bends and good welds. Told them its their last chance. Im too much of a nice guy perhaps.

[wde_bdy]

Way too much of a nice guy. If I picked up my car with that abortion attached it would have been thrown back at them and they wouldn't have been paid a cent. Since it sounds like you have already handed over the money you are in a much much weaker bargaining position, then paying extra to get what you asked for really puts you on the back foot. If they are willing to let that sort of work out of their workshop then they are unlikely to happily refund you, will likely force you through the cost and time of the disputes tribunal to get anything back and I doubt it will be the full amount.

Callum

[Vertigo]

My problem is that I simply had to pick up first thing in the morning and then rush to work. No chance to ask for it up on the hoist to inspect everything. Basically had to take it off their hands, inspect when I had time, and then report back.

Im pretty appalled that they assumed they could get away with it, but Im as stubborn as they come, so I will fight them on it if it doesnt come back perfect.