My First Alum. TIG welds

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so the trailer fix is my first alum tig weld that I used filler on, I bought a spool of wire and found that my TA 181i will not push 4043 alum wire, so I twisted some up and used my old IdealArc roundtop to tig it, after I ran the bead I lit up again and smoothed it out a lil cause it didn't look that great, its my neighbors trailer, so I needed it to look ok. so then I went out the next day and bought some 5356 rods, 1/16 3/32 and 1/8, on the plate I ran some beads with the filler, first I used a 3/32 Radnor e3 tungsten that's what all the lil dots are from, it would NOT strike an arc, I popped in a thoriated and it lit right up and after a few runs, I was able to make an ok dime stack, scratch start sure is hard to get lit with the ol round top lolMiller Syncrowave 210 w/CK FlexLoc 150  3/6/14ESAB PCM 1125 Plasma CutterAtlas 12x36 LatheACER 9x42 3hp millHarig 612 Surface GrinderDRINK Machine              welding&fabrication
Reply:Next time try grinding out all the old weld and than have at it.Your results will be much better....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Originally Posted by zapsterNext time try grinding out all the old weld and than have at it.Your results will be much better....zap!
Reply:+2Just gonna crack again.  Dollars to donuts, you didn't penetrate though to the root of that crack.  I'd add a truss if possible as well.  Gotta think about what forces caused the crack in the first place.Kudos to you for trying.  Round tube has to be the hardest thing to make good looking tig welds on.  That continual angle change just screws the pooch.  When I got to the point where I could consistently lay down aluminum beads on the flat, I attempted tubing and made the worst looking crap you've ever seen.  Think I dipped the tungsten 4-5 times doing one T joint on some 1" 6061 tubing.Last edited by Drf255; 06-06-2013 at 05:22 AM.TA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:Thanks for the input The force that caused the crack are from throwing logs in the trailer and hitting the back. And those are the top rails o the trailer and they are just rolled and whoever made it welded in little triangles in each corner yeah I agree shoulda ground it down but i was in a super rush I didn't get the welder back together until like 1:30am and then didn't wanna grind cause of the neighbors. I had to use a hammer to beat the corner back together it was about 1/4 in gap when brought over. So now that I have some actual filler rods of a different stronger alloy when I get back home from work next week I think I will bring it back over and clean it up, looking at the back side of the original weld they did t have proper penetration. You could see the edges as well as about 1/32 of flat unwelded area. Question, what tungsten do you recommend I use with my machine and what type of point, remember I have to scratch start and that radnor e3 crap wouldn't start at all kept sticking. The thoriated lights Right up though but maybe there's another type thAts even easierMiller Syncrowave 210 w/CK FlexLoc 150  3/6/14ESAB PCM 1125 Plasma CutterAtlas 12x36 LatheACER 9x42 3hp millHarig 612 Surface GrinderDRINK Machine              welding&fabrication
Reply:You can use a piece of copper to scratch start with.  Tungsten wont get contaminated or stick then.   Not sure on your other questions.
Reply:I got copper but you think it will work on ac? I don't have any issues on dc I just swipe the filler between the work and electrode works great but not on ac lol i will try the ac copper start thanks for the tipsMiller Syncrowave 210 w/CK FlexLoc 150  3/6/14ESAB PCM 1125 Plasma CutterAtlas 12x36 LatheACER 9x42 3hp millHarig 612 Surface GrinderDRINK Machine              welding&fabrication
Reply:If you have no intention of buying a tig with foot control and like welding with your Idealarc - keep an eye out for a Miller HF-15-1 high frequency spark box.  No scratch start needed and much easier to weld aluminum with it.I have one - they work great  But I did buy an old tig welder later (my avatar)...with foot control.Dave J. Attached ImagesDave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:I seen a Lincoln hi freq box on eBay for 600 used older model but i ain't spending that kinds money on that I'll save and get a dynasty 200dx or invertec v205t ac/dc may get a pedal for my ta welder but no alum wit it......Miller Syncrowave 210 w/CK FlexLoc 150  3/6/14ESAB PCM 1125 Plasma CutterAtlas 12x36 LatheACER 9x42 3hp millHarig 612 Surface GrinderDRINK Machine              welding&fabrication
Reply:I wouldn't spend that either Lowest I've seen the Miller versions sell locally is about $200 to $250.Dave J.Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:would the miller box work on the Lincoln?Miller Syncrowave 210 w/CK FlexLoc 150  3/6/14ESAB PCM 1125 Plasma CutterAtlas 12x36 LatheACER 9x42 3hp millHarig 612 Surface GrinderDRINK Machine              welding&fabrication
Reply:It's just a "pass through" box that gives you the high freq along with the current the welder puts out.I've used mine on three different welders so far: century AC/DC, miller thunderbolt AC, and a really old Forney AC machine.Here's two of them - the old Forney welded aluminum the nicest of the three Dave J. Attached ImagesDave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:So is there a torch button to start or a pedal with just an on off functionMiller Syncrowave 210 w/CK FlexLoc 150  3/6/14ESAB PCM 1125 Plasma CutterAtlas 12x36 LatheACER 9x42 3hp millHarig 612 Surface GrinderDRINK Machine              welding&fabrication
Reply:On simple ones like mine, there is no start control.  You lay your tig torch flat right where you are going to weld, tip it up quick and it will light right up.  Although I generally just put the tungsten close to the metal and it starts.Dave J.Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:what about stopping? do you have to pull away? ive done that a few times and put the torch right back over the weld area for some gas and from about an inch away the arc lit off lol, whoa!! luckily I still had my hood down, I seen jody from weldingtipsandtricks actually made a crude foot pedal cutoff switch but he was able to retain shielding which im not sure it does any good when I break away and put the torch back over the weld, im sure it helps a tiny bitMiller Syncrowave 210 w/CK FlexLoc 150  3/6/14ESAB PCM 1125 Plasma CutterAtlas 12x36 LatheACER 9x42 3hp millHarig 612 Surface GrinderDRINK Machine              welding&fabrication
Reply:Originally Posted by chevydylwhat about stopping? do you have to pull away? ive done that a few times and put the torch right back over the weld area for some gas and from about an inch away the arc lit off lol, whoa!! luckily I still had my hood down, I seen jody from weldingtipsandtricks actually made a crude foot pedal cutoff switch but he was able to retain shielding which im not sure it does any good when I break away and put the torch back over the weld, im sure it helps a tiny bit
Reply:I read most of your post and looked at the pictures, Sometimes people try to make things support or do more work than they really can structurally.......Maybe figure out why it failed before welding it. A simple gusset here and there will improve the joint dramatically.......5356 should have worked,I like 4943 over 4043 now that it is available...  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock
Reply:Thanks B-C I didn't actually use the 5356 on the trailer I will when I ge home lol i need a do-over. I used some 4043 .030 mig wire tripled and twisted up to weld on the trailer. As far as gussets I'm not sure he will want anything on the inside of the trailer but I may be able to put some over the top of the rails and follow the original dimensions I go the wheels turnin in m head I don't like the idea of putting them under the rolled part idk seems better across the top being as it actually started to tear the sheet metalIt failed because he was throwing 30-40 pound logs into the trailer and they would smash into the back even on steel over time it would take it's tollMiller Syncrowave 210 w/CK FlexLoc 150  3/6/14ESAB PCM 1125 Plasma CutterAtlas 12x36 LatheACER 9x42 3hp millHarig 612 Surface GrinderDRINK Machine              welding&fabrication