Metal question.

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I am a beginning student at a vocational school for Welding. I've welded before and in the class (only stick) and the instructor says I have extreamly good beads. I am very satisfied in my welds and they have been tested on a brake press and welds didn't break. I am going to build a bumper for my buddies truck and had some questions. The bumper is mostly for looks but I am going to put tow hooks on it that he will be able to use. I was thinking 1/4" aluminum for the bumper and mig weld it. Dimensions are 67 3/8" wide, 12" tall and 6" deep. Any suggestions or anything you'd do different?
Reply:You got a mig machine capable of welding alum?Otherwise I have done it but I used tig.Weld like a "WELDOR", not a wel-"DERR" MillerDynasty700DX,Dynasty350DX4ea,Dynasty200DX,Li  ncolnSW200-2ea.,MillerMatic350P,MillerMatic200w/spoolgun,MKCobraMig260,Lincoln SP-170T,PlasmaCam/Hypertherm1250,HFProTig2ea,MigMax1ea.
Reply:U will need to bolt the tow hooks on as they will be steel.  Look at any full size truck and u will see the hooks go through the bumper and bolt to the frame Make sure they are bolted thru the bumper to the frame.  1/4" aluminum is not that strong for a bumper build.  What u want to do is a mistake if u have never welded aluminum before...   not to mention the material cost is expensive.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 soutthpawU will need to bolt the tow hooks on as they will be steel.  Look at any full size truck and u will see the hooks go through the bumper and bolt to the frame Make sure they are bolted thru the bumper to the frame.  1/4" aluminum is not that strong for a bumper build.  What u want to do is a mistake if u have never welded aluminum before...   not to mention the material cost is expensive.
Reply:Still cheaper than stainless! If you go the aluminum route, plan on using stainless fasteners and try to put some sort of isolator between the frame and the bumber. Mild steel against aluminum causes galvanic corrosion. I have seen aluminum parts bolted to steel that have corroded each other into basically powder.