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The finished tube, beaded on each end, is shown attached to a hose. Double clamps are cheap insurance.
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Here is what you will need (left to right). A tubing cutter (or a hacksaw), a muffler pipe expander, the length of tubing you require (muffler pipe in this case), clamps and hoses. The tools shown are less than $15 each and can be found at discount tool stores.
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Cut a 1/8-inch wide slice off the end of a piece of your tubing. The cutter makes it easy to keep it straight, but you can do the same thing with a hacksaw if you are careful.
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Here is the slice. You will need one for each end of your tube.
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File a bevel on one side of the slice (or you can do this on a bench grinder). Be careful and wear goggles.
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Place the slice over the middle of the pipe expander. As you tighten the end bolt, it expands, stretching the slice outward. Stretch only as far as required slipping it tightly over the end of the tube.
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Here is the slice, with the bevel to the inside, placed on the end of the tube.
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Weld the slice to the end of the tube using a small tip on a gas welder. This is pretty simple welding and requires very little filler rod. The aim is to keep the slice in place, not provide a watertight seal.
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Let the tube cool, then bevel the outer end to make hose installation easier.
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Check-fit your hose. If everything is okay, you can paint the tube with a heat-resistant paint or have it powder coated.
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Here is a water outlet with a beaded end. All water connections must be beaded or the hose will come off sooner or later, which can cause other damage.
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