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Welding aluminum with a spool gun

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Mark W. View Drop Down
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    Posted: 10 Jan. 2021 at 7:09pm
Does anyone here have experience welding aluminum with a spool gun? I would be welding .065 wall square and rectangular tubing. Looking for advise.

I'm not a great welder I can stick together stuff from 16ga to 1/4" but its never real prudy. The project I have in mind would be cost prohibitive to have someone else do the welding. So trying to figure out my options.

A TIG machine is not in my future.
Chug A Lug
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Post Options Post Options   Thanks (0) Thanks(0)   Quote otto Quote  Post ReplyReply Direct Link To This Post Posted: 10 Jan. 2021 at 8:00pm
I worked in a shop that had a Miller spoolmatic gun. I recall it wasn't the most precise device and was difficult to dial in. It was very splattery, sparky to use. I was fixing a truck cab that had been fixed before.

Do you have a lot of scrap to practice on? The cleaner the metal the better.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote oldtime Quote  Post ReplyReply Direct Link To This Post Posted: 11 Jan. 2021 at 12:19am
Even if it’s a great quality machine you really need a TIG on .065.
Lincoln square wave 200 is a good unit.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mark W. Quote  Post ReplyReply Direct Link To This Post Posted: 11 Jan. 2021 at 1:25am
This is what I am finding out. I was just trying to be lazy. Ill go back to figuring out how to assemble it mechanically.
Chug A Lug
1948 2A Body Customized
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1957 CJ5 Frame Modified
Late 50's 134L 9.25"clutch T90A D18 (1.25") D44/30 flanged E-Locker D25 5.38 Since 1962
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Post Options Post Options   Thanks (0) Thanks(0)   Quote duffer Quote  Post ReplyReply Direct Link To This Post Posted: 14 Jan. 2021 at 3:56pm
Originally posted by oldtime oldtime wrote:

Even if it’s a great quality machine you really need a TIG on .065.
Lincoln square wave 200 is a good unit.

Yep.  I use a Lincoln 250 Magnum spool gun and you can do a decent job down to 1/8" and with a light touch, .090.  Any thinner and it's just about impossible not to blow holes through it.

On the plus side, MIG is a much faster process for thicker sections.  I was a bit surprised to see that's what Aqualu uses to weld up their aluminum Jeep tubs/fenders/grills.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote oldtime Quote  Post ReplyReply Direct Link To This Post Posted: 14 Jan. 2021 at 5:16pm
John, do you have AC pulse arc ?
I agree .090 is minimum thickness for all but the very best welders running pulse arc AC.

The pulse arc allows for a cooler deposit than normal dip transfer mig weld. While the other mig method of “spray arc” would be totally in appropriate for thin aluminum.
Currently building my final F-134 powered 3B .
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Greaser007 Quote  Post ReplyReply Direct Link To This Post Posted: 19 Jan. 2021 at 4:23pm
    Way back, in the early '80's i bought a spool of aluminum wire to run in my Linde 225 mig-master, to weld up a badly cracked hood for a Ferguson TO-20 ? tractor.   From my memory,  i did get it welded, but if my memory serves me correctly, it was quite a challenge.   Seems like i had to 'stitch-weld' in short bursts.   Nowadays, i know of a good local welder who likes aluminum, and i have no idea what he uses.

    I have not used a spool-gun yet.   But, i think the guys who weld the aluminum hulls on white water inboard river boats do use spool guns.   And they are mostly using a minimum of 0.125" material too.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote oldmansimek Quote  Post ReplyReply Direct Link To This Post Posted: 20 Jan. 2021 at 12:03pm

I hate saying this but I have seen the alumiweld rods that you use mapp gas (kind of like brazing) with do some pretty impressive stuff and hold up really well.  Having said that I only use tig for anything under 1/8".  I think I saw someone mention aqualu and being surprised about the spool welding, I have a good friend who builds and repairs over the road aluminum fuel tanker trailers and he uses a spool on everything.

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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mark W. Quote  Post ReplyReply Direct Link To This Post Posted: 20 Jan. 2021 at 6:07pm
I have a real nice MAPP torch setup and its virtually worthless as MAPP is unavailable any where around here. Some 8-10 years ago one of the 4 big welding supply outfits we have in Salem told me they could send my tank off and get it filled but the cost was insane like $250 for my 30" tall tank.
Chug A Lug
1948 2A Body Customized
1949 3A W/S
1957 CJ5 Frame Modified
Late 50's 134L 9.25"clutch T90A D18 (1.25") D44/30 flanged E-Locker D25 5.38 Since 1962
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