5052 Aluminum marine application project. Some questions.

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I am looking to do some final research into a planned aluminum project.  I have most of the drawings completed.  Going to build a cardboard template to do some final testing for fit.Then I need to do some testing and practice on the same type of scrap aluminum that I will build the project out of to determine I am completely comfortable and capable of performing the task.The project is for a marine application of 5052 alloy.  Essentially I am building a watertight box.  5 of the six sides will be 0.100 thick with the final side being either 0.100 as well or 0.125.  That determination will come into during the final testing phase.What is the best filler rod to use with 5052 alloy specifically to be used in a marine environment?
Reply:5356 is a common marine wire.OzDynasty 200DXMiller 210 Spooly
Reply:I generally tig all my boxes made of 5052 with 4043 rod. Outside corners I use a1/16 or 3/32 rod diameter. Amperage about 125 amps. Welder is dynasty 350. Pulse set at 1.0 ,frequency 180 balance 60   What welder you using. Do u have a break. I try and bend as many sides as possible to reduce welding. Dan
Reply:Thanks for the suggestion on the filler rod.I have a HTP Invertig 201.  While it is no Dynasty 350, it does have a few of the nice pulse features and adjustability of balance and frequency.I do have access to a brake and was hoping to do just that. . . Bend as many of the corners as possible to save on the welded seams.  Most of the welds will be outside corner joints.  There will be a few inside fillet welds.  The inside fillet weld will most likely be 0.100 to 0.125.I am going to start by practicing the outside corner welds.  Depending on how they go, I will make a determination on how I will proceed with the rest of the project.
Reply:Unless it is a high heat application, this is definitely a job for 5356.  What is the purpose of this box?  Fuel tank, flotation pods or...?Remember, the trick with the outside corner welds is the keyhole.Last edited by bassboy1; 04-14-2013 at 07:39 PM.Who is John Galt?
Reply:The goal is for floatation pods that are custom sized and fitted to my specific hull.  There are a couple of generic ones that are available on the market, but each comes with it's own compromises.  If I can practice enough and be comfortable enough with my welds, I won't have to accept the unwanted compromises.  If I can't, i will first look for a qualified local welder to take on the task.  The last option will be to mount the generic floatation pods.Last edited by canderso; 04-14-2013 at 08:02 PM.
Reply:Quick question. Why two thickness of material. Why not all .125?
Reply:The boat hull is 0.100.  The other available pods are manucatured with 0.100 as well.I was thinking the 0.100 would be plenty, but thought the back of the box that will eventually attach to the transom could be a little beefier at 0.125.  I am not opposed to doing the whole thing out of 0.125 though.Thoughts?Last edited by canderso; 04-14-2013 at 09:14 PM.
Reply:Originally Posted by candersoThe boat hull is 0.100.  The other available pods are manucatured with 0.100 as well.I was thinking the 0.100 would be plenty, but thought the back of the box that will eventually attach to the transom could be a little beefier at 0.125.  I am not opposed to doing the whole thing out of 0.125 though.Thoughts?
Reply:Originally Posted by candersoThe boat hull is 0.100.  The other available pods are manucatured with 0.100 as well.I was thinking the 0.100 would be plenty, but thought the back of the box that will eventually attach to the transom could be a little beefier at 0.125.  I am not opposed to doing the whole thing out of 0.125 though.Thoughts?
Reply:indawoods. . . like indaswamp? or the inda-boys from the duck chat forum?  Thanks for the info.  Hoping to finish my paperboard/cardboard mock ups this week.  Hopefully, supplies this weekend and some form of testing beginning next week.bassboy-  thanks for the tips.  Definitely will plan to put in a bung for testing and such.  Maybe I will just do the whole thing out off 0.100.  I was trying to determine whether to do the flush fit or one inch up.  I will plan for one inch up from the bottom with a slope up towards the end of the pod.What has your experience been with mounting the pods flush to the sides vs one inch in from the side?
Reply:Originally Posted by candersoWhat has your experience been with mounting the pods flush to the sides vs one inch in from the side?