This is part of a ZF install that grew to include a new motor, brakes, 3 point seat belts, floor insulation, hydroboost, etc. That left zero money to pay a shop to do my exhaust. I bought a J pipe from Summit and had at it. Creating a merge pipe was beyond my skill level until I found some 3" flew duct tube, and that allowed me to make a templet.

 

Just wondering if your using a mig with flux core wire ? If so, I would consider setting it up to use gas. You won't believe how much better it will weld. You can use C02 gas for welding steel to save some money. Not meaning to be a dick but your welds will get better if you shorten up your arc gap, that's why your getn all the spatter. Then work on your heat & speed setting with some scrap pieces.

 

Thanks for the tips! I know they look bad. After reading your post, I tried different distances from wire to tube, various heat settings too, and was able to find the settings that actually produced a nice bead! Thanks for the help. Btw, I threw away that entire piece.

 

If you are starting over that is also not the way to merge. A right angle in to a pipe that small is terrible for flow.