How to Weld Exhaust Flanges Square Without Warping

Welding an exhaust or turbo flange square is deceptively hard. The heat pulls the flange as it cools, so a face that started flat ends up warped, and a warped flange leaks no matter how good your bead looks. The fix is to hold the flange dead flat and on center while you weld, which is exactly what a flange welding fixture does.

Why Flanges Warp

• Uneven heat input pulls the flange face as it cools
• Tacking in the wrong order twists the part
• Holding a flange square by hand or with clamps is inconsistent
• A warped sealing face leaks, and then needs to be re-faced or scrapped

The Fix: A Flange Welding Fixture

The Brockett Built Flange Welding Fixture holds your flange flat and square to the tube while you tack and weld, so the sealing face stays true through the heat cycle. You get a leak-free, repeatable joint without chasing warp after the fact.

• Holds the flange square to the tube for a flat, leak-free sealing face
• Repeatable setup, so every flange comes out the same
• Built from heavy stock to resist flex and hold alignment
• Made in the USA

How to Weld a Flange Square

1. Set the flange in the fixture and square it to the tube.
2. Tack in a cross pattern (like lug nuts) to balance the heat.
3. Weld in short, opposing segments rather than one continuous pass.
4. Let it cool in the fixture before removing, so the face stays true.

FAQ

Will this stop my flanges from leaking?
A warped sealing face is the most common cause of flange leaks. Holding the flange square while you weld and cool keeps the face flat, and a flat face is what seals.

What flanges does it work with?
It is built for common exhaust and turbo flange work. Message us with your setup if you are not sure.

Get the Brockett Built Flange Welding Fixture ($400) →

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Welding tube and pipe joints too? See our guide on welding tube joints straight with a positioner and the Tube Fixture.

Designed and built for working fabricators by Brockett Built in central Illinois.