K321 Rebuild

[hdeloach]

If you don't have or can't weld--get a close nipple,90 degree elbow ,and short nipple. Cut the threads off one end of the short nipple then just screw it together.

 

[rfunk]

Thanks for the ideas, guys, I'll try something like this. My welding skills are so-so, older stick welder, so I'll have to be careful to not burn through the pipe wall.

 

[rfunk]

Closer look, the port threads were cross-threaded at some point. However, the threads in the stud holes cleaned up beautifully with a tap. Just removed rust, not metal. I'm going to see what a 1" NPT tap will cost me, otherwise I'll try making a flange.

 

[bwilkinson]

Thanks for the ideas, guys, I'll try something like this. My welding skills are so-so, older stick welder, so I'll have to be careful to not burn through the pipe wall.

IF welding it is better to use Black pipe, as it is easier to weld. IF welding galvanized grind off the outer plating before welding, and when welded it may crack easier.

 

[rfunk]

Been busy, only getting at this every couple of days. Gasket, two layers, proramic stel core, made. Carbide burr and grindstone in Dremel did the job. Now for the most critical part - fixturing to weld it up.

 

[rfunk]

Got it put together late Saturday, tested it before the rain tonight. Muffler is now solid. Had to use the socket head bolts, and even make a "special" tool to tighten the bolt under the elbow. 1/4" hex screwdriver bit cut off fit perfectly, and could get a wrench on it to turn it. I'm not a great welder, but got it done.