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Black Iron Junction

Square Tube Bending

Bending square tubing is often required when doing some metal working at home or at work and finding an easy and effective way to bend your tubing will eliminate the need for expensive joints and connectors.  You also don’t want to have to spend money on replacement steel tubing, so getting it right first time is important. Don’t skip this step, find a good way to bend or shape metal.

In order to bend the tubing, you will first want to tape the one end with duct tape.  After closing off the one end, you will want to fill it with sand before closing off the other end with duct tape too.

Mark off where you need the bend to be and place the tube in a vise at the point where you want the bend to be.  You need to torch a three inch length of the tube with a torch from the point where the bend will be until it is red hot.

Next you will want to slide a larger tube over the one that you are heating up which you can use as leverage in order to bench the orginal.  As you bend the leverage tube towards yourself, you may be required to heat up the original a few times in order to get the shape and bend that you need. It can often be possible to need a special construction job.

Exhaust Tubing: Street Cred And Beyond

Replacing the exhaust tubing system in your car can give more benefits than you can imagine. Not only can it increase your vehicle’s power and performance values, but it can also increase its street cred. Custom pipes are not only attractive, but it can also help your engine produce a more primal and therefore more attractive sound. I have equipped my car with these, and I had absolutely no regrets with my decision. Are you looking to install one for yours? Here are some notes that can be said about these upgrades.

Custom Exhaust Tubing System = Street Cred

Street cred is a term usually bandied about by those involved in the car customizing scene. Having good street cred means your car is grabbing attention (and in the process, respect) in the streets. As a customizer, that’s arguably the biggest praise you can receive from onlookers. But how can a set of pipes, most of them located underneath your vehicle, out of sight from onlookers, grab attention? This is mainly because installing aftermarket tubing help enhance the sound of your engine. A lot of people find the growl resonating from an engine with a well-sorted out exhaust system to be super-attractive.

More Than Just Street Cred

Installing an aftermarket exhaust system brings street cred because of the “delightful noise” it produces. But can it actually benefit your car in a performance standpoint? The answer to that question is a resounding yes. There’s a reason why most of these aftermarket parts take inspiration and technology from motorsports. This is because a well-selected exhaust system can greatly enhance an engine’s performance, especially during high-speed, high-stress situations. This is because an enhanced piping system allows for better gas flow, releasing them in a much quicker pace. Improved exhaust gas flow is beneficial for the engine to “breathe” easier, allowing for increased output.

Possible Drawbacks From Installing An Aftermarket Exhaust Tubing System

Theoretically, a custom exhaust system should be beneficial at all times. But on practice, that is not always the case, especially if you install an ill-fitting tubing system for your car. Take for example, pipes with large diameters. Theoretically, it should help my engine run better because it relieves it of excess air back pressure. Having pipes that are too large can hamper an engine’s performance at low speeds because of the elimination of what tuning experts would call the “scavenging effect”. A compromised low-rpm engine performance makes daily driving difficult and even inefficient. Also, some of these systems eliminate the use of a catalytic converter, which can make your car emit more harmful emissions and even make it illegal to drive on the streets.

Can I Install One By Myself?

For the do-it-yourself junkies out there, the answer to that question is yes, as long as you have the tools and know-how to do it. There are bolt-on pipes that just have to be welded into place to use. And for the more adventurous, you can construct and install your own pipes from scratch. However, I would recommend that you do proper evaluation first before selecting an exhaust system. Consulting a mechanic is a good first step to determine the ideal exhaust tubing system for your car.

Structural Tubing Uses

While it is true that structural tubing is used all around us, very few of us take any notice of it.  Without structural tubing, the architectural and industrial industries would not be what they are today.  The wide range of construction materials as well as the array of different shapes are as numerous as the uses for it from simple everyday things such as railings to shopping carts.

Steel is the most commonly used construction material for tubing and when it is manufactured, it is run through rolled metal coils in order to produce the various shapes.  Once the coils have been cut, they need to be welded together in order to produce a long tube.  In addition to the standard steel, you can also find structural tubing made from carbon, alloys, aluminium and brass.  Each has its own advantages and disadvantages and is used for a range of applications.

While we are most commonly aware of circular tubing, there are other shapes used including square, rectangular as well as oval tubing.  If you look under your vehicle, you will notice a number of components manufactured from square tubing including the framework of the vehicle itself.

Most structural tubes are chemically coated which not improves how long they last but in certain cases actually also helps with their performance.  The various chemicals used include phosphorus and sulphur and are applied in order to prevent such chemical reactions as oxidation from occurring.

Although structural tubing is one of the types of square tubing available on the market, you can also find square tubing that is used in the transfer of high pressure fluids and gases and is called pressure tubing.

Square Tubing

Tubing is most commonly described as a long hollow cylindrical or square pipe that is used to convey fluids, gases or other substances.  Tubing and piping are very similar except for one distinctive difference where tubing is considered to have a tighter engineering requirement that a pipe.  Hoses are flexible, whilst tubing and piping are generally rigid and constructed of metals and hard plastics.

Tube manufacturing generally starts with coils of steel which are slit to the correct width for the size of tube that is required.  This strip of coil is called a skelp and by passing it through a series of rolls, it is cold-formed into a tubular shape.  An electric resistance welder is used to join the edges together and as no filler is used in the welding process, the entire tube is consturcted of the parent material.

There are three different classifications or classes of manufactured tubing:-

  1. Seamless – produced by extrusion or rotary piercing
  2. Welded or Electric Resistant Welded (ERW)
  3. Drawn Over Mandrel (DOM) – formed from cold drawn electrical resistance welded tube which has been drawn through a die and also over a mandrel to produce weld integrity, dimensional accuracy and an exceptional surface finish.

There are also a wide range of standards to which the tubing is manufactured both from an industry perspective as well as from government standards.  The various standards are important to consider when understanding what each is capable of as well as their material compositions.

Any installation that involves hydrogen for example will require the use of copper and stainless steel tubing that has been factory pre-cleaned (ASTM B 280) and is certified as instrument grade.  Without such precautions, hydrogen could react with oxygen causing the metal to become brittle and unstable.

Stainless Steel Exhaust Tubing

Replacing or modifying your engine exhaust is an easy way to spruce up the life and look of your car. Stock exhaust systems often use unattractive steel tubing to ventilate the exhaust from the motor. The tubes are often too thin, and suffocate the engine. Often they are also poorly insulated, which causes your engine exhaust to cool before exiting the system, which causes it to exhaust at a lower velocity. This reduced speed will cause lower engine volume, and inferior engine airing.

Stainless steel exhaust tubing utilizes the material properties of stainless steel to offer better engine exhaust performance. The most common exhaust material is aluminized steel. Aluminized steel has a specific heat of around .11 BTU/lb*F which is lower than stainless steel at .12 .11 BTU/lb*F. This means that for the same amount of stainless steel, it will absorb and less of the exhaust heat, and therefore your exhaust will remain at a higher temperature as it exits the exhaust. Higher temperature means high velocity, which means more sound, and is generally considered healthier for your engine. This is especially when using high octane fuels.

Aside from superior thermal properties, using stainless steel as exhaust tubing provides other benefits as well. Stainless steel was originally developed because of its resistance to rust. It is mixed with chromium, which when exposed to air reacts and forms a thin film of waterproof alloy, that prevents water from contacting the iron and forming rust. When gasoline combusts it creates heat, water, and soot. Because the air ventilating out of your engine contains significant amounts of water, it is important to be using a material that is resistant to oxidizing via water.

Of course all physical properties aside, the most important reason people love using stainless steel as exhaust? It looks great. Stainless steel is just that, stainless. It is easy to clean, does not corrode, and will last for a long time. Other materials will gather soot, and all sorts of other debris and are hard to clean.  It also easy to coat with other materials, namely chrome. Chrome plating is popular in the automotive industry because of its beautiful shiny look and how it protects the underlying metal from corrosion.  Stainless steel is a bit more expensive than alternatives, but nearly always the extra money with worth the better protection, improved car performance, and great new look that it will give your newly modified car.

Flexible Exhaust Tubing

There are different kinds of flexible exhaust tubing in the market. Most of these are used for the exhaust systems of automobiles. The reason for its flexibility is that there are many different types of exhaust systems that are arranged independently. There is really no standard that dictates how long or how wide a car’s exhaust chamber should be. Hence, flexible exhaust tubing fits the requirements of various exhaust systems because it can bend across obstructing tubes and components, unlike hard tubes.

Flexible exhaust tubing is usually installed between the engine and the muffler, and is used to decrease engine noise and vibration. It also absorbs the muffler pipe thermal expansion and shock, thus protecting your muffler from damage and shock sustained in bumpy rides. It can also compensate for misalignments in the exhaust converter because of its flexibility. No matter how much the under chassis experience stress, these are just absorbed by the flexible exhaust tubing, proving resistance to cracks, blow outs, and leaks.

Another great advantage of flexible exhaust tubing is that it eliminates the expensive costs of customizing exhaust tubes for the car. It bends where you need it to go, and is tagged at very cheap costs, which is better than installing a custom furbished pipe.

The best type of flexible exhaust tubing available is the stainless one. It is as expensive as a galvanized or aluminized type, but will certainly last longer. The flexible exhaust hose is measured through the diameter inside. It is designed to wrap over an existing pipe and is fastened with a clamp. Band clamps are preferred over u-clamps for the reason that it has a lesser chance of leaking and has the capacity to stretch itself and give a tighter seal. It is available in sizes starting from 1.5″ diameter and up. For most diesel exhaust systems, using a size of 3.5″, 4″, or 5″ is advisable.

Flexible exhaust tubing is available online. There are many cheap products from China that have passed strict international quality standardization procedures. Cheap flexible exhaust tubing is also available in a local dealer near you whenever you order in bulk, but you have to cut the lengths by your own.

Flexible exhaust tubing has many advantages than just being flexible. It’s definitely cheaper than having a customized pipe installed in your car, it is more resistant to shock, and it reduces engine noise and absorbs pressure. Cheap and reasonably effective, it fits every automobile because of its flexibility.

Exhaust Tubing

There are plenty of reasons to replace or upgrade your current car, truck, or motorcycle exhaust tubing. You can increase the power of your engine by providing better airflow. If the outbound air is restricted it will suffocate the engine and not allow air to be taken in, which is crucial to combustion. Aside from allowing better airflow, larger tubes will create a much more robust engine sound. Often the muffler along with the exhaust tubing are designed to silence to engine, and make it as none-noticeable as possible. If you want an engine that lets it’s presence known, the first step  would be to buy larger exhaust tubing and replace the factory stock muffle and tubing.

On motorcycles the exhaust piping is often directly visible, and can add to the attractiveness of the bike. There is a whole art to exhaust tubing, and a wide variety of materials and finishes to choose from. The most popular is stainless steel because its ability to combat corrosion and last a long time. Water, which is a by-product of combustion, drains out of the exhaust pipe along with soot, carbon dioxide, and excess air. Water typically is very corrosive to iron and steel, but not stainless steel. Stainless steel exhaust pipes are iron with a touch of chromium. The chromium reacts with the air and creates a resistive film over the metal, protecting it from water and where it gets it “stainless” name from. Other exhaust tubing metals include aluminum and titanium.

Of course many exhaust pipes don’t just use chromium in the steel, they are also chrome plated, which is to say they are covered with a film of chromium. This provides a corrosion resist cover for you exhaust and even more desirable: a beautiful silvery, reflective finish. Polished chrome has a unique and striking visual look. Chrome plating can be expensive, so likely you will only want chrome plated exhaust tubing on a motorcycle, where the pipes are visible, there is little point in putting chrome plated tubes under your car unless you specifically intend to show off the bottom of your car.

It is also possible to craft your own custom exhaust tubes. You can buy stainless steel, steel, or other metal tubes, and bend them with either a press, or tube bender. Tube benders are surprisingly inexpensive and easy to purchase. Also, most well equipped machine shops will have them and will bend the tubes to your specifications. Obviously this can be fairly tricky to install and I wouldn’t suggest doing it unless you are familiar with custom car modifications.

The air handled by the tubes is fresh out of the engine. This means it is full of energy with both latent heat and hot air. Latent heat refers to the energy in the hot water created as a by-product of combustion. Steam is very corrosive and will damage your pipes unless you use the appropriate materials for your pipes. Soot can also clog your tubes, much like plaque clogging your arteries. The soot builds on the walls and can choke the airflow. When the engine cannot take in air it cannot completely combust the fuel and loses significant power. For these reasons it is often worthwhile to replace or clean your exhaust tubes.

Exhaust Tubing: Should You Get One?

The debate of whether or not to install aftermarket parts such as exhaust tubing on cars is a raging one. But if you are going to ask me, installing parts like this should always be a good idea, provided that you install the right parts. This is my case on why you should go for aftermarket piping on your car. In addition, I would also give some tips and precautions before you go ahead and equip your car with such a system.

The Case For A Custom Exhaust Tubing System

The main argument for those who are skeptical on how aftermarket parts work is the fact that practically all car makers spend years developing their cars to attain such level of precision. And while that is true, there are some holes to that argument, or to be more specific, mechanical flaws. Because let’s face it, it’s rare for a car to achieve perfection right out of the gate. Aftermarket parts are created in order to improve on the things the factory wasn’t able to improve on when it left the assembly line. Making improvements on the exhaust system is one step towards making your car a more formidable tool on the road.

Advantages Of Improving Your Exhaust

Theoretically, an engine works just like a human being. If you provide means for it to breathe, it’s just natural for its performance to jump up. This is why for both tuners and those involved in motorsports, the first thing they try to improve is the intake and exhaust systems of the car. This is because it’s the easiest way to improve a car’s performance without significantly altering its main working parts such as the engine, chassis, body, and gearbox. Not only does installing the right exhaust system increase horsepower, but it also improves fuel economy and other engine-related numbers. As a bonus, installing a custom exhaust system improves your engine’s sound significantly, increasing its wow factor in the process.

Things To Watch Out For When Modifying Your Exhaust Tubing

In this part, I would mention some things you must take note before installing a new tubing system. The saying “bigger is always better” doesn’t apply here. While it’s true that piping with bigger diameters can significantly help air flow and consequently performance, installing pipes that are too large can actually compromise performance, especially at the low-rpm range. Also, some find the sound generated by a car with custom exhausts to be noisy and distracting. I would also strongly suggest that you keep the catalytic converter intact, or else you’re going to risk the increased production of harmful gases and can even render your car illegal for road use.

Installing Tubes By Yourself: Possible?

In a word, yes. It is possible to install your new exhaust system by yourself. There are bolt-on pipes that you’ll just have to weld into the existing exhaust system. Some even go as far as creating a custom-made exhaust system. But if you are not quite sure, you can have a mechanic install it for you. Just make sure to install the right exhaust tubing for your car, and you’ll be alright.

Square and Rectangular Tubing

The primary function of square and rectangular tubing or pipes is to transport various substances such as gas and liquids and can be used for a range of applications including water systems, gas pipelines and oil refineries.  Most often the tubing in question is manufactured from iron, steel and brass, but others for more domestic applications can also be manufactured from fibreglass, ceramic, plastic and concrete.

When it comes to the manufacture of metal tubing, there are a range of different manufacturing standards that need to be achieved in order for the products to be used in various industries.  The three specific types of manufacturing methods include seamless, cast and also welded.  Cast pipes have all but become obsolete although there are a small number of manufacturers who still use this method.  When it comes to economical piping, the welded pipes are an excellent choice but they are not as strong as the seamless pipes and therefore cannot withstand the same amount of pressure.

Pipes Sizes and Calculations

In order to confuse issues, there are two very different measurement standards for piping around the world.  Europe have their own standard while the countries of North America adhere to another set of rules.  This is due to the different units used for measurements.  In European countries the measurements are in millimeters whilst the American measurements are calculated in inches.

Bending Square Tubing

Bending square tubing is a specialized field and is not easy to achieve domestically.  The integrity of the metal must be maintained throughout the bending process to ensure that the end product is as strong and durable as the original.  There are a range of specialists who deal with the bending of square and rectangular piping and customized machines are required in order to achieve a professional finish.  The end result is used in a wide range of construction and engineering industries and is a popular method of obtaining strength and durability whilst being able to work around corners.

Aluminium Tube Bending

If you have tried to bend a tub, you will be aware of how tough it can be to get a perfect bend on a tube. The most important factor in tube bending is the amount of pressure that is exerted on the tube to make it bend. If too much pressure is exerted, the tube can break or can collapse and this is not a good result when working with expensive metals.  There are different ways in which tubes can be bent and you can use manual or automatic options for tube bending. Black Iron Junction has been in the business of working with aluminum for many years and can bend any type of aluminum tube according to the requirements of the customer.

Aluminum tubing is used extensively in factories to carry raw materials or finished products from one end of the factory to the other for processing or packaging. In factories, tubes don’t run in straight lines and there will be the need to bend the tubes wherever required. By using state of the art technology and machines, Black Iron Junction can bend the tube while ensuring that the integrity of the tube remains intact. While bending or stretching any metal, there can be areas that can become weak spots and therefore it has to be examined to ensure that the strength of the metal is not compromised. Black Iron Junction uses modern detecting techniques to check the tubes that are bent thoroughly and will deliver the product only if it passes their stringent security checks.

One of the problems that are often seen in tube bends is the reduction in thickness of the metal tube at the bends. One side of the tube gets compressed and the other side gets extended and this can cause certain weak points in the bend that can rupture when put under pressure. Black Iron Junction uses X-ray and other methods to identify if the integrity of the tube has been compromised and if so; the tube is rejected and is not sent to the customer. Only if the tube that is bent passes the various check that Black Iron Junction does will the tube find its way to the customer and onto homes or factories.

Working with an aluminum tube is not easy and the process of bending an aluminum tube is a lot tougher than other metals. The soft nature of the metal always adds to the risk of the bend collapsing and therefore the whole process has to be done very carefully. Black Iron Junction has experiences in working with aluminum for many years and it uses that very knowledge to help them bend aluminum tubes and maintain the integrity of the tube. By using technology and the experience that they have in working with aluminum, Black Iron Junction ensures that the bend in the tube is done properly and as per the requirements while making sure that the tube is still able to withstand the temperature and the pressure that it will be subjected to.

Manual tube bending is ideal if you are only going to bend one or two tubes. But if there are a lot of tubes that have to be bent, it is a good option to opt for machines that will help you bend the tube. Using CNC tube bending machines will help you to get precise bends while not damaging the integrity of the tube. Companies like Black Iron Junction use CNC machines of most of their purposes and this allows them to stay well ahead of their competition by providing services that are unmatched. At Black Iron Junction the importance of technology is understood and the company ensures that it provides its workforce with the latest technology to help them produce high quality aluminum products.