Stick vs. wire feed for welding tube headers, what did y'all pick?

I had to choose between stick welding and using a wire feed MIG setup for some exhaust tube headers on a job last month. I went with the wire feed because I heard it was cleaner and faster for thin wall stuff. It turned out okay but I spent a lot of time cleaning up spatter and fighting with the settings. A buddy at the hall said I should have stuck with 7018 rod for better penetration on the joints. Now I'm wondering if I made the wrong call for that specific project. Has anyone else tried both on tube work and had one come out way better?

3 comments

3 Comments

uma_williams14d ago

Man I think people overthink headers way too much. I've welded up plenty of tube stuff with both and honestly it's not like one is gonna make or break the job if you take your time and clean the metal right. The spatter is annoying with wire but you can avoid it by slowing down a bit and using a contact tip that's not all worn out. Stick is fine too but it's slower and you get more cleanup on the inside if you blow through.

lindag3314d agoTop Commenter

Wait, you're saying stick is actually fine for thin wall tube headers? I always figured it was way too easy to blow holes with 6010 or 6013 on that gauge metal unless you were a total savant. That's blowing my mind a little honestly, because I've been scared to even try it on a friend's set.

murray.jana14d ago

@lindag33 it's more about technique than being a savant. 6013 on DCEN with a tight arc will let you weld headers without blowing holes if you keep the amperage low. 6010 is trickier because it digs in more, but you can run it hot and fast with a whipping motion and it actually works fine. The real trick is getting the fitup tight so you're not trying to bridge gaps with filler.