hello, i am new to the forumn tonight. Glad i found you, and hope someone can help. i am not new to welding, but do not do it everyday. some days i weld like a pro, others i dont think i should be allowed to weld at all! i am making exhaust pipes for my bike, and am having a difficult time with the butt joints, and the size transitions. the pipes start at 2", step to 2-1/4" and end up at 2-1/2". i had a tubing company bend the specific radius of each size i was looking for, but when it comes to joining them at the size changes i am having to finish them by hand. the result is a smooth step, but not even in terms of around the pipe. keep in mind that not only are the pipes visible, they are a focal point, so perfection is the minimum. as far as the butt joints go, finishing them to a look as if no joint is even there is the goal, however, seems an impossible task. i have tried every different sanding device available to man, but by the time i grind / sand off the weld it is noticable in at least one spot or another. if i fill it in it only gets worse due to under cut from the new weld. any tips on filling pinholes? they usually grow into a nightmare also! the list of problems go on... PLEASE HELP! for equipment i have a Snap-On muscle-mig 250, arCo2 gas, i also have a spool gun for aluminum & stainless, and a tig setup for this welder, and get the same results. the pipes are .065" wall thickness. ANY AND ALL TIPS/TRICKS WILL BE APPRECIATED. THANKS
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