[BTromblay]

Originally Posted by Peter Tommasini

Bill there are a few techniques to weld alluminium I have seen it in Italy in 1967/68 at Scaglietti, and also at Carrozzeria Touring in Milan *Italy) when I visited there .
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Years later, then living in Australia I did see and practice the way that the English tradesman did it in England at Aston Martin ,Rolls Royce. .. They did it a bit different but with the same results.

So here I will try to explain how

In Italy two people would weld a long and large panel, by one person holding the two panels together, and manipulating the panels so the next person (after preparing and fluxing the two panels) would run the oxy torch over the joint and melt the two parts together. Then the panel would get replenished and hammered up on a Maglio , then finished off by hand, this method is very hard to do, and I have only seen a few people doing it right.
I my self cannot get it .
I have seen two other methods from England tradesmen , The first method was... to turn (with a hand made tool) a very small edge upwards on each of the edges to be welded, then fuse those two edges together, ( again with oxy) meaning that the two upwards edges where used as filler rod. Then after washing the flux thoroughly, the panel would be planished on a stake dolly and then wheeled up . when with this method the panel was finished ,on the inside of the panel the penetration was nearly invisible , it looked like a mark done with a wet finger on the ally. I have tred that and it works rather well .

The next method is the normal conventional method to cut file and bevel the two edges , adjust and tack (again with oxy) then weld with a HOT but soft flame (this is called carbonizing flame ) then simply planish and wheel. The problem with this method.... YOU NEED to have the torch really really working well, WHY ? 1st...... because you do not want to have too much penetration, because that is only going to upset the planishing, 2nd...it might either have a cold weld (meaning it's too high) or a too hot weld causing holes and uneven weld

If you where to ask me which method I like better.. I would say that, once I have decided on the type of shape I will be welding, I would then decide which method I would use
Peter

Hi Peter,

Thanks for the information, it is always great to get a detailed description on how the work is performed.

I'm gas welding aluminum now with excellent results. Most of my parts are smaller in size, 2' x 3' (600mm x 900mm) so it is easier to manipulate the panels. So far, the process I like the most is to tack in several spots at one end of the seam. I adjust the panel, planish as needed and them weld the same area about 1/2" (12mm) long. I can then move the panel up and down, in and out as needed and fuse tack along the seam until it is tacked from one end to the other. Planish and adjust as I need, then one weld full length from one side to the other with filler rod. Light planish/wheeling as needed and body file off the balance of the weld. Due to Federal aviation regulations, I'm required to leave a visual portion (weld bead) of the weld seam. I metal finish the out side of the panel smooth to the surface and leave the weld bead on the inside of the panel. If I get undercutting or a small low spot next to the weld, I will push up what I can, with out using a pick hammer, (I don't like pick marks on the back side of my panel). If I have small lows, 1/8" 3mm or smaller, I use an aluminum solder to ill them in and metal finish the surface. Makes for a clean appearance for the customer who can be Fuss Pots over little detail items.

I still have more to learn, but getting better every day.

Thanks

Bill