Welding aluminum?

[tirwin]

I don’t know much about welding. It’s been on my list of skills I’d like to learn one day.

I keep seeing videos advertising aluminum using a torch and low temp rods that they sell. Harbor Freight carries them. I was going to have someone weld up the holes in my bumper before I get it repainted. Just wondering if this actually works or if it is gimmicky. How does the strength compare to an actual weld?

[ClickClickBoom]

Advertising hype. Welding is welding, soldering is soldering, brazing is brazing, all are different and have their particular uses. Without knowing what the rod is composed of it’s a toss up. Seen that stuff, might be ok for your bbq handle, but that’s about it. I have TIG, MIG, OXY, as well as plasma torches in my shop, never seen that stuff at the weld store. Gimmick, bet it would be fine for non structural applications like bumper hole filling though.

[Bill Douglas]

I tried.

Some aluminium would weld fine, and others wouldn't. Sort of like a blob of molten aluminium that wouldn't stick to the other bit of aluminium. A friend said I should have been using flux. It was getting complicated so I gave up.

And no, it wasn't like on the videos although the brand name was the same.

[tirwin]

Thanks, guys.

Pretty much what I expected to hear.

[Dpmulvan]

There’s several different types of aluminum some are weldable some are not.

[dad911]

I've used the rod with success of fresh new thinner aluminum. However, it takes alot of heat, an aluminum bumper being a big heat sink, would be very difficult.

Why not epoxy if the holes are cosmetic? Unless it's structural, then get a new bumper.

[cabmandone]

It works pretty well on thicker aluminum but I don't think I'd have the stones to go after my bumper with it. To get the rod to flow you need to have the material (your bumper) hot enough to melt the rod. It's a pretty fine balancing act.

[r lane]

To weld aluminum, you need some degree of theory and understanding of the craft, materials, and equipment, but most of all, practice, lots of good practice.

[gwinnch]

Call some boat repair shops-some of those are used to welding aluminum. Don't know if it's the same kind of aluminum, though.

[Locker537]

I'm a true novice, but welding aluminum is a lot of fun.

Unfortunately, it's not the cheapest to get started. You'll want a decent TIG setup for aluminum. Granted, it's probably a great time to learn!

[Trackrash]

I have used something like that HF stuff in the past. It is not actually welding. It is a type of soldering, or brazing, if you will.

It CAN work, IF your metal, is a compatable alloy and it is VERY clean, not like an old bumper. The real danger is overheating and ruining part of your bumper.

You could get some and try it on some scrap aluminum......

You could take your bumpers to a pro. However I would confirm from someone who has welded a Porsche bumper that it is do-able. Some aluminum alloys don't weld well. I am talking using TIG here.

Or get some JB weld.....

[Jack Stands]

I’d check with mb911 for advice. The rods being sold seem more like soldering than weld8ng.

[donbecker1234]

Originally Posted by tirwin

I don’t know much about welding. It’s been on my list of skills I’d like to learn one day.

I keep seeing videos advertising aluminum using a torch and low temp rods that they sell. Harbor Freight carries them. I was going to have someone weld up the holes in my bumper before I get it repainted. Just wondering if this actually works or if it is gimmicky. How does the strength compare to an actual weld?

Aluminum can be a bit more difficult due to the way it conducts heat.

Another issue complicating the bumper repair would be that it's thin, and the heat from any welding operation makes welding on any thin metal more difficult.

TIG is preferred due to the amount of control.

I've welded aluminum before, but it was with MIG.

If you're interested in learning to weld, IMO it comes down to having good equipment, and lots of practice.

Here is what I have

It runs on either 110 or 220, and I have the additional gun for it that lets me do MIG Aluminum. I think this is the gun.

To add, there is a very big difference between being able to weld when you know EXACTLY what metal the two pieces are versus not knowing what they are and having to "read" the welds as you go to adjust the setup you're using.

Welding is so cool though, in that it opens so, so many doors to different ways for you to fabricate things out of metal, instead of being limited to only bolts, rivets and glue.

[dap930]

When I did restoration/slantnose conversion on my '77 many years ago, I found corrosion on the inside the rear bumper. When I cleaned these areas up with a sanding disk, I found what looked like thin layers of aluminum that were bonded? together that would peel off as the sanding progressed down through the corroded areas to get through to clean metal. I am not sure if later bumpers were made this way or if the front bumper is made that way. So, if it is a layered construction, can that be welded?

[Trackrash]

Originally Posted by dap930

When I did restoration/slantnose conversion on my '77 many years ago, I found corrosion on the inside the rear bumper. When I cleaned these areas up with a sanding disk, I found what looked like thin layers of aluminum that were bonded? together that would peel off as the sanding progressed down through the corroded areas to get through to clean metal. I am not sure if later bumpers were made this way or if the front bumper is made that way. So, if it is a layered construction, can that be welded?

The only way to know is to try. Pros will want to test on some similar scrap metal before welding on your expensive piece.

I imagine these bumpers have been welded before. It's just a matter of talking to someone who has done it.

[tirwin]

Originally Posted by donbecker1234

Aluminum can be a bit more difficult due to the way it conducts heat.

Another issue complicating the bumper repair would be that it's thin, and the heat from any welding operation makes welding on any thin metal more difficult.

TIG is preferred due to the amount of control.

I've welded aluminum before, but it was with MIG.

If you're interested in learning to weld, IMO it comes down to having good equipment, and lots of practice.

Here is what I have

It runs on either 110 or 220, and I have the additional gun for it that lets me do MIG Aluminum. I think this is the gun.

To add, there is a very big difference between being able to weld when you know EXACTLY what metal the two pieces are versus not knowing what they are and having to "read" the welds as you go to adjust the setup you're using.

Welding is so cool though, in that it opens so, so many doors to different ways for you to fabricate things out of metal, instead of being limited to only bolts, rivets and glue.

There is an auto restoration school out in the midwest that offers 1 & 2 week classes to hobbyists when their normal students are out for the summer. My buddy and I have been saying we want to go take their welding class sometime.

My uncle was a master pattern maker at a foundry. He has been restoring cars since I was a toddler. He can fabricate anything. There are so many things I’d like to do and not having that ability myself holds me back.

I’m watching paint dry at home. I have a lot of projects I’d like to be making progress on but can’t yet. Waiting on parts, need to order parts... I was just wondering if this was something I could try to tackle.

[Discseven]

Tim... I worked with Muggy Weld---butane torch, rods and flux. Aluminum can't be thin sheet as it's difficult without much practice to keep the sheet from melting.

Material greater than 3/16 is doable. Bond is strong than base metal when done right. Like anything, does take some practice to get familiar with.

Not sure what brand the Harbor material is but my experience with Muggy Weld was good on thick material. Finished material files and sands nicely.

[Davep1]

I’d check with mb911 for advice. The rods being sold seem more like soldering than weld8ng.

[tirwin]

Thanks for the feedback. Probably don’t need to experiment with the bumper. Just wondering if it was something I could try while I have some down time. Guess I need to find some other trouble to get into.

[Lake Guy]

I had the holes on my bumpers welded up. I own a fab shop and we do structural and architectural aluminum welding. We sand blasted first as aluminum needs to be very clean. Got the oxidation out. MIG or TIG could work but we started with the spool gun and it turned out fine - that’s MIG. Aluminum is far more difficult than steel and metal composition does matter. Not sure what the bumpers are made of but our standard set up for 5000 series was good.

Go ahead and have it done as it’s not too difficult.