How to Install a Weld in O2 Sensor Exhaust Bung

How to install a weld in exhaust bung which is typically used for 02 sensor, but can have other uses as well. These exhaust bungs can usually be purchased for a couple dollars at your local auto parts store, this one was purchased from a local exhaust manufacturer wholesaler, along with the rest of the parts as well. I’m redoing the whole exhaust system on this truck which is a 98 Ford Ranger. This truck is equipped with 2 oxygen sensors, therefore it has post and pre cat sensors. The pre is installed on the exhaust manifold and the post is located after the cat which I’ll be installing here. This pipe will be attached to the catalytic converter and there is usually a specific distance where that o2 sensor should be located. For this I am matching the factory distance which was about 6”. I am also taking the expanded portion of the pipe into account which is why you’re seeing me mark the distance at 7.5”. This will also depend on what type of o2 sensor is used. Some are heated, therefore they can be further away. Non-heated sensors require heat from the engine or catalytic converter to function correctly. Keep in mind, when a sensor is too close, it can also overheated therefore creating a premature failure on that sensor. #exhaust #autorepair #emissions

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Tools/Supplies Needed:
-drill
-drill bits
-center punch
-hammer
-carbide grinding bit
-mig welder
-wire brush
-grinder
-abrasive pads
-wrench

Procedure:
-considering this is a pipe, there is a greater risk for the drill to wander, so use a center punch to mark the hole
-I will be using a step drill for the hole
-in order to start out that hole, a center drill should be used
-the sensor should be installed anywhere from a horizontal position to the top of the pipe
-meaning between the 9 and 3 o’clock positions
-once that hold has been drilled, unfortunately it’s still not large enough for this particular bung as it’s intended to have that lip fit within the pipe
-in order to make it larger, I’ll just use a carbide grinding bit which can be used on a drill or die grinder
-increase the diameter of the hole until it’s the correct size
-in order to keep that hole symmetrical, I used a rubber o-ring closely matching the bung’s diameter with a marker
-considering the bung is flat and is being installed on an arched surface, this can be a little tricky to weld
-this is aluminized exhaust pipe, it has a coating which needs to be removed before welding
-I’m just an abrasive pad on the angle grinder
-also clean up the bung to remove any factory coatings
-now to weld that bung in place, I used a piece of wood to hold it in place, then applied a couple tack welds
-for this I am using a flux-core welded, therefore there is no gas shielding and slag will be present
-remove the slag using a wire brush, this must be done before applying more welds as slag can cause inclusions
-an anti splatter spray can be used to prevent splatter from sticking
-apply beads and change your position as needed
-clean up the welds with a wire brush, then apply more beads when needed
-for installation of the vehicle, the sensor must be installed between the 9 and 3 o’clock position as it avoids the chance of moisture damage, along with any interference from being damaged when driving
-ideally, if possible meaning there is no interference with the floor or any other components on the vehicle, it’s best to have the sensor in the 12 o’clock position

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