FastKat

iTrader: (10)

I want to try and build my own aluminum crossmember, probably out of 1/8". 3/16" or 1/4" boxed aluminum tubing. I don't trust myself to weld something that critical, however cutting and fitting the pieces will take a lot of time. I want to tack weld the crossmember together and have a professional run the beads along the seams.

I have a stick welder that I have used before but that's it.... what can I use to tack these aluminum pieces together?

Thanks, -Dave

FastKat

iTrader: (10)

Oh yea... my dad has a Miller (I think) MIG welder that I have never used before but I would really like to avoid using that if possible.

smoknta

No you cant stick weld aluminum. You need a Mig setup to run Aluminum. Or you can set you stick welder up to run as a Tig and tack it that way.

BTL FED

iTrader: (9)

You would need a mig w/ an aluminum spool gun, or a Tig welder to weld alum.

FastKat

iTrader: (10)

Set my stick welder up as a TIG? How would I go about that?

I guess I will start asking around for an aluminum gun for my MIG, too...

Any other info?

Hot Rod

Or you can buy stick aluminum electrodes

http://store.cyberweld.com/alel40.html
Never bought anything there just using it as an example. I get all my stuff local.

Use DCEP polarity and practice on a piece. And be sure to clean your aluminum workpiece thoroughly. <- can't stress that enough. And be ready to run a fast bead.

SS2win

iTrader: (11)

the Al rods burn fast. if you are quick you might be able to tack with them but dont I recommend it.

FastKat

iTrader: (10)

Do you need some sort of gas to stick weld with aluminum?

Jaymz

I think you will need an AC stick welder to weld AL. If I were a betting man I would bet that you have one of the Lincoln DC tombstone stick welders. You won't be able to do aluminum with that machine.

You will definately need 100% argon gas. I have migged smaller al running .030 wire thru a .035 tip with 100% argon. It worked for spot welds but looked rather ugly. I wouldn't trust it for a critical part.

jdustu

iTrader: (2)

like "hot rod" said, you can stick weld aluminum using dc+......i personally haven't done it, but from what i heard talking to folks who have, it burns super fast and globs up at the start, two characteristics that would not be good for tack welding......

do you have an oxy/acetylene torch? you can gas weld aluminum with flux and filler, or some folks have done it with an aluminum stick rod.....but this works best on pretty thin stuff....your best bet would be converting the mig for al, but it would be more expensive.....