Custom Bed Side Exhaust Pipes - (Not So) Exhausting - Tech

Now comes the tricky part. Unless you have a jig for welding tubing, it's a bit touch-and-go when it comes to welding two bent sections of tubing in the correct "phasing." For this instance, I simply set the tubing on the ground and used a heavy piece of square tubing as a backup.

Using a level, I adjusted the vertical section until it was plumb, checked that the flat piece was plumb in the opposite plane, and marked both pieces at the seam.

Once marked, they are slipped into a piece of angle iron and clamped in place. By making two or more markings across the seam, it reduces the possibility of "clocking" either of the tubes incorrectly. Using a piece of angle iron as a jig surface ensures that the two pieces of tubing line up correctly around the entire circumference so that they can be butt-welded efficiently.

With the vertical section tacked together, the long, 8-foot straight section can then be tacked onto the assembly using the same makeshift jig.

Now that I've got one complete side tacked together, it's time to mock the side pipe up against the bed to check for fitment and to mark where the mounting hardware will be installed.

Wanting to keep the pipes nice and tight against the bed, I used 2x2x1/4-inch angle iron to act as locating spacers while the pipes were clamped in place.

At this point, it's important to ensure that the bottom of the pipe is centered in the hole before moving on...

...as well as being parallel to the stake pocket and evenly spaced between it and the cab.