Good god, you want to talk about hell on Earth? It's working on something that depends on skill, knowledge, specific tools, and proper materials while having none of the above. All the same, I've finally got the exhaust system together in working order.
It's as primitive and looks as horrible as you might expect, since I only had the flux core welder available. In my defense, though, it's a shock that I managed to end up with something usable and looking like it could last long enough to do the job until I get to a point to get a good system in place. With the combination of what I've learned and the template that the end product can provide, I think I'll be able to put together a respectable replacement when the day comes (assuming I have access to a MIG setup).
The main delays I ran into largely stemmed from having to COMPLETELY redo both sides, end to end, more than once. I would get one side plumbed proper, then find the other side was out of whack after looking at it from the one angle I overlooked before. Fixing the other side required changes on both, and this just kept going on and on.
Of course, when you get locked into that kind of soul-crushing ping pong match, you become demoralized and even more error-prone, which will instantly double the work hours spent on your project as you fuck, unfuck, refuck, and defuck things -- some of which never needed to be messed with in the first place. The eyes are only as good as the seer, and without a stunt double to take the reins, I had only stubbornness, stupidity, and fury to carry me through to the end.
Problems with the welding material ended up being just as much of a delay and obstacle as my cognitive troubles presented, though this didn't come up until around the same time as the last update I posted. The wire I had been using was actually working out perfectly, despite the slim wall thickness of the tubing I was using. As I was able to make my welds easily, quickly, and with nearly zero burn through, I was rocking right along. Then the spool ran out.
I had to switch to a different brand of wire, since what I had been using wasn't locally available. Ordering more of what I had been using wasn't a practical option, so I was stuck with using a different brand. The first spool was okay. . . It had more of a problem with burn-through, but not enough to stop me in my tracks. The subsequent spool's were worse, not only for burn, but also because it seemed like more of the filler material shattered and sprayed all over the place than was actually fusing with the work material. No amount of setting or position change fixed the problem, but I was eventually able to get it to a point where I could at least use it.
Now, if you're wondering why I didn't post any updates through all this, the answer's pretty simple: I didn't want to write it, and you wouldn't want to have read it. Chances are good that I would've just kept spinning my wheels, trying to rationalize things while I wrote, and shit would've taken twice as long as it already has. So with that, I can't say I intend to do daily updates from here, though I will have updates to share soon enough.
Coming soon: walkthrough of reconditioning a Motorcraft distributor. This will probably come after I get done bending and installing new brake line from the front to the rear (yes, really; found signs of the old line leaking, probably expanded when I got too close when doing the floor boards), but before I get the carb installed and tied in. Initial startup and break in are going to be happening in the near future, and I hope to capture the moment on bit film.
I'll keep y'all posted, but do me a favor: post a comment or even just email me if you actually read this mess that I write. It's a big motivator to know that other people are interested in seeing how this shit show unfolds. Have a good one!
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