Durafix for Allum Tubes

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First let me say hello to everyone on the fourm.I am Rob AKA TheKraftyRhino. 5-6 years ago I was a Welder Repair Tech for a company and I got my certs from Miller in Linc. Elect as a repair tech. One thing I learned on my trek threw the world of welding is that just because you can fix them don't mean you can use them lol. Although I a fairly good @ stick and mig welding and damn good @ gas welding. Tig never took to well for me. I guess with practice I could have become a better Tig welder. It was nice back in the day to have access to all the welders but times change and I have moved on from the field. Yet my need to create never left my blood so I was considering taking on a new project to build an Electric/manual Buggy.I am kind of a design on the fly type and I like to iron out design bugs in the field as opposed to trusting my pen and drafting tools. Yes that does set me apart from other mech. engineers who think if it works on paper it must work in real life.My prototype will be a work in progress until I iron out all the bugs and mechanical issues. I now live in a Townhouse and I don't think even if I could afford a welder to do aluminum my housing board might get a little upset if I am making arcs on my deck.I got some 1/8 wall 3/4 Aluminum tubes and I need to weld them together. Kinda in the fashion of a bicycle frame. I know in the long Run I am going to need to take them to someone and get it welder properly but I need to know.QuestionsWill something like Durafix or HST2000 hold the tubs to support say a 300LB payloadHow long would you figure this will last b4 needing a propper weld job (If it will work)Will a Shop be able to go over my Duarfix welds with the propper weld latter once I am done?
Reply:1.  My guess the bonded joints (notice I didn't say welded) will not support that load.2.  Once you use that crap on aluminum, you can forget about ever being able to properly tig weld the joint.Better to seek out a tig welder and have him tack the joints while you progress with the project.  Either that, or build it in wood until you get the bugs worked out and then go to the aluminum.Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:Sundown is absolutely correct about contaminating the aluminum with the "glue".  If you don"t want to Tig it, you could use something like a Miller 252 mig unit and a Miller 30a spool gun with aluminum wire and just do spot mig welds during the fit-up stage.  Since you are using 1/8" thick tubing, you can also use that same spool gun to make the final full welds.  Mig welding with the spool gun takes nowhere near the special skill that Tigging requires.....plus the spoolgun is quick.  Probably about 3 grand to buy the whole setup.Miller Syncrowave 350Millermatic 252/ 30A spoolgunMiller Bobcat 225g w/ 3545 spoolgunLincoln PowerArc4000Lincoln 175 Mig  Lincoln 135 Mig Everlast 250EX TigCentury ac/dc 230 amp stickVictor O/AHypertherm 1000 plasma
Reply:Originally Posted by DougAustinTXSundown is absolutely correct about contaminating the aluminum with the "glue".  If you don"t want to Tig it, you could use something like a Miller 252 mig unit and a Miller 30a spool gun with aluminum wire and just do spot mig welds during the fit-up stage.  Since you are using 1/8" thick tubing, you can also use that same spool gun to make the final full welds.  Mig welding with the spool gun takes nowhere near the special skill that Tigging requires.....plus the spoolgun is quick.  Probably about 3 grand to buy the whole setup.
Reply:Originally Posted by DesertRider33While mig with a spool gun is a great, easy process to use in structural aluminum plate and other straight joints of descent thickness, it is a rather difficult process to use for small diameter round thin wall tube, especially with a big bulky spool gun, in various positions, with various difficulty of joint access.   I find tig is easier to use for these type of joints.