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In this video, I attempt to repair an exhaust header (driver side/left) from a 1996 Chevrolet C1500 2WD 5.7L V8 pickup truck. The owner is rebuilding his truck and asked if I could bring this header back to life. Someone had previously tried to weld it, but the repair was messy and left the tubing brittle and rusted in several spots. That made welding tricky, especially using .035 wire instead of .030, which would’ve given me better heat control. Still, I wanted to show the process as real as possible — the good, the bad, and the lessons learned. In this video you’ll see me: Identifying the damage on the header Cleaning and prepping the old welds Welding and patching brittle/rusted cracks or holes in the tubing Learning the importance of proper prep and a solid ground clamp I kept the process mostly unedited to show that mistakes happen, and sometimes you just have to make do with what you’ve got. If you’re interested in DIY exhaust header repair, welding practice, or fixing old Chevy truck parts, this video might help you out