I'll be undergoing my custom exhaust work as soon as my Y pipe arrives.

My question to anyone here with experience in their exhausts:

Should the joints be 'butt welded' or 'overlapped'?

The Pro's and Con's seem obious, but I am new to this particular experience so feel free to correct or inform if any of the info I've gathered seems incorrect!

Butt weld:
Pros --> Less restrictive if cut at proper angle and welded correctly
--> Less material (spread ends, overlap pieces, etc.) as such cheaper

Cons --> More difficult to master
--> Less strength
--> Higher possibility of burn through when welding


Overlap:
Pros --> Higher strength
--> Easier to weld and fit
--> Leaves more room for error in cuts

Cons --> Restrictive due to differing sizes and edges, etc.
--> Cosmetically displeasing (more of an IMO)



Like I said, please post what you think! My biggest concern... if I perform butt welds, will they crack on me? My welds will be performed by a experienced welder, and the cuts, I assure you will be precise to within a 16th, I'm taking my time on this one to make sure it's perfect.

For reference, I'll be using 2.5" SS pipe, SS TIG welding sticks, 3/8" steel flanges in stock locations, and all the OE mounting locations.


Thanks in advance for your thoughts/opinions!

Matt

 

Overlap.