.070 aluminum whats the best way to weld it? it is 5052. The only machine I have access to weld aluminum is a 110v Lincoln 140 with a spool gun. I have 4043 and 5356 .035 and 100% argon Needless to say I have found this a tricky unit to use to plug some rivet holes and such. I have been thoroughly cleaning with stainless brushes and wiping with acetone. Is this a tricky metal to make a butt weld with? I find it common to get a crater at the end of the bead or it will develop a crack. I put some big patches to fix some gashes in the hull. I used 1/8" to patch and essentially was making a 1/8 to .070 butt weld.


any hints tips or tricks to weld this shit nicely with a spool gun?

pretty sure that machine isnt gonna weld 5356, the miller 211 didnt have enough wire speed to keep up so im sure that one prolly wont either since its smaller.

Overlap the pieces if possible. This will give a more forgiving hot spot. Swap to .030 wire too

Thanks for the info. As far as overlapping is that a good idea on the hull bottom? I know it's not a race boat but I'm assuming the less' ridges 'the better I made my patches from floor brace to brace so for part of the patch I would have some backing metal. I will pick up some .030 4043 and give it a whirl. Is tig the best way to weld aluminum? I flat out don't have very much experience with aluminum at all

Tig welding it would be easier just be careful not to get it too hot or the puddle will fall out. It will also take cleaning it well with a solvent cleaner and a stainless wire brush. Also a high frequency welding machine will make it alot easier.

If I read this correct, you want to "re-sheet" the bottom of a .070 hull? You also want to weld the new sheet to the bottom of the damaged hull to help out?

In my honest opinion, it doesn't matter if your using .030 or smaller wire in 4043, that sucker is going to warp like hell. That 110v machine will pour the coals to it. Its not a pulse machine. You will have to bounce around ALOT. Meaning, you will have to weld about 3" ( if you can sustain a 3" weld without blowing through the hull) then move forward 2' and repeat. Work your way all around the hull until you have completely finished. But if your going through that much trouble, just build another hull.

You can use a flange tool to step the outer edge of your patch and install it from the back side. That would keep things flat. Yes a tig would be awesome but not nesasary. Check Eastwood if you go looking for tools

If you already have tig experience then there you go

If it were me and I had access to the machine I'd tig it. Like said before aluminum will warp a lot worse that steel and the heat transfers farther out and faster with aluminum than steel. Get a scrap piece of aluminum and practice on it.

I'm looking at a Lincoln square wave 200 anybody use one of these?