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Old 06-16-2014, 12:08 PM
Maxakarudy Maxakarudy is offline
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Join Date: Feb 2013
Location: Origin of the wheel, UK
Posts: 630
Default Mig welding aluminium

Hi folks,
I thought I'd share a liitle job I did the weekend, a repair on an aluminium wing (fender). This was due to a previous bodge by a body shop many moons ago, who pop riveted and bonded it together. I had to make the repair panel for this wing and weld it on proper styliee...
My daytime job is fabricating signs, mostly in aluminium, folding panels then welding up the corners, grinding them up and sanding of the excess weld. We don't tig or gas to weld them up, for various reasons to boaring to into, mig welding is my prefered method, we weld mostly 2mm & 3mm ali.
So when presented with the dilema to tig or mig the repair panel, as I'm more confident with mig due to the super sophicticated double plus synergic welders I use, welding 1.5mm ali didn't put the fear of God into me.
I tacked the panel every 20mm then I ran the 20" of seam in 2 strikes, I was concerned about blowing it to bits, but I worried unecessarily, I could have done with a tad more power, but I erred on the side of caution (got scared really). As you can see the weld is pretty proud, but no abnormal distortion. After grinding the bead down, I blued the panel up and planished everything, just like normal, there was no weld cracking, although the penatration on the back didn't allow me to get it as nice as I have would liked, but that was due to not being able to grind the weld off the back due to the inaccesabiliity of getting inside the panel, I could get a dolly in, but that was it, also the last 8" was completely inaccessable due the A post. I'm very happy with the result, but would not consider using it all the time, just thought I'd give a go.

photo_1 repair.jpg

photo_2 repair.jpg

photo_3 repair.jpg
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