Aluminum stick example

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I am installing a 6.0L gen III engine into my 72' Chevelle. The cast aluminum pan does not clear the tie rods and needed a few windows installed. I do not have an a/c tig set-up but I do have plenty of aluminum stick electrodes.I was pressed for time and only grabbed one pic during the project. I'm just showing another handy use for aluminum smaw. Attached Imageshttp://www.facebook.com/Knappmobilewelding
Reply:That may be the best aluminum stick I've ever seen. Nice, functional fix.GravelThe difference between theory and practice is that in theory there is no difference.
Reply:Thank youhttp://www.facebook.com/Knappmobilewelding
Reply:What type welder and how many ampsThe main thing is not to panic or get excited Bobcat 250, X-Treme 12VS,  MM211Meltabo, Milwaukee,Porter Cable,Dewalt,MakitaVictor O/A, Ingersoll-RandEvolution Rage2, 40 amp PlasmaLincoln 225 AC/DC
Reply:Having used stick aluminum rod before, your welds look good to me.
Reply:Tried those sticks too and never made them work. But I only bout a few and since I have good welders for both mig and tig I didn't put in much effort. Yours look good.Yeah, I know, but it'll be ok!Lincoln Square wave 255Miller Vintage mig30a spoolgunThermal Dynamics Pacmaster 100xl plasmaSmith mc torchEllis 1600 band saw
Reply:Been burnin them for years. Nice lookin welds. Something that will help is a little preheat. Propane torch or O/A. I like to use a oily thumbprint outside of but close to the weld zone. When the thumbprint smokes, weld it. Will really flow out better for you. will give you an 8+ . Good job.To ride, shoot straight, and speak the truth. This was the ancient law of youth. Old times are past, old days are done, but the law runs true oh little son.Winpower 180 DCSA-200 redfaceXMT-304
Reply:Having never run one of these rods, what polarity is used? Also what is the thinnest material you could weld using this process?Miller 211Lincoln 225 buzzbox
Reply:The cast pan is 3/8" thick and the aluminum plate is 1/8". The machine is a trailblazer 302. 3/32" rod, reverse polarity, 65 amps with the arc dig setting low. I don't use pre-heat on thin stuff like this. I also cool it down after a few beads. As far as the thinnest material, I'd say 1/8" if you keep it cool enough.http://www.facebook.com/Knappmobilewelding
Reply:They will run on AC too Rick V did a huge thread on these a free years agoStill got a whole bunch of these for an Aluminum Stick off competition at a future Weld-o-rama.Last edited by soutthpaw; 11-25-2014 at 07:37 PM.Tiger Sales:  AHP Distributor    www.tigersalesco.comAHP200x; AHP 160ST; MM350P,  Spoolmatic 30A; Everlast PowerTig 185; Thermal Dynamics 60i plasma.  For Sale:  Cobra Mig 250 w/ Push-pull gun.  Lincoln Wirematic 250
Reply:Originally Posted by KnappweldThe cast pan is 3/8" thick and the aluminum plate is 1/8". The machine is a trailblazer 302. 3/32" rod, reverse polarity, 65 amps with the arc dig setting low. I don't use pre-heat on thin stuff like this. I also cool it down after a few beads. As far as the thinnest material, I'd say 1/8" if you keep it cool enough.
Reply:Originally Posted by sled dogBeen burnin them for years. Nice lookin welds. Something that will help is a little preheat. Propane torch or O/A. I like to use a oily thumbprint outside of but close to the weld zone. When the thumbprint smokes, weld it. Will really flow out better for you. will give you an 8+ . Good job.
Reply:I've never tried them on ac. I will next timeLast edited by Knappweld; 11-25-2014 at 11:09 PM.http://www.facebook.com/Knappmobilewelding
Reply:Originally Posted by GravelThat may be the best aluminum stick I've ever seen. Nice, functional fix.
Reply:Nice lookin alum stick welds
Reply:That looks gooood!
Reply:Thanks everyone. Aluminum rods are very sensitive to amperage settings. Its also very easy to trap slag in tight joints. The flux flows very quick and likes to race in front of the puddle.http://www.facebook.com/Knappmobilewelding
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Reply:Originally Posted by sled dog Something that will help is a little preheat. Propane torch or O/A. I like to use a oily thumbprint outside of but close to the weld zone. When the thumbprint smokes, weld it. Will really flow out better for you. will give you an 8+ . Good job.
Reply:Originally Posted by InsanerideNever tried those electrodes but will have to sometime. Do you use nose grease or will any grease in my garage work? My thumbs dont get oily but sometimes sweaty. Thanks sled dog.Knappweld, thanks for sharing.
Reply:Like sled dog said, just get in there and practice. Aluminum stick is overlooked/ignored but for field work, misc repairs, etc it is a great process to learn.http://www.facebook.com/Knappmobilewelding
Reply:Originally Posted by InsanerideNever tried those electrodes but will have to sometime. Do you use nose grease or will any grease in my garage work? My thumbs dont get oily but sometimes sweaty. Thanks sled dog.Knappweld, thanks for sharing.