1st time Aluminum tubing TIG

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Try not to laugh, first time trying to tig around a tube LOLStraight edges are easy...turns out tubing is not!Here is a project for my younger brother.  His hot rod is going to be 1000+ horsepower and he needed his blower tube welded.  (we will find out the actual horsepower numbers in a couple weeks after the dyno run and pro tuning)The completed tube he purchased in steel and did not like the look.  So he brought aluminum over to me.The set-up:1/4 flange plate16 gauge 2.5" tube (which we did the fitting)11 gauge 4" tube bent at 45 degree angleAirco 300 set about 200 amps, using a pedal so used less3/32 red tungsten in a WP26 flextungsten grind was about 45 degrees and it balled very smallstainless brushed and acetoneMain problems were:inconsistent torch angle due to inexperience with tubinginconsistent heat due to inexperience with different thicknessesfrequent start/stops (about 6 on each)tacks were very hard to do with different thicknessesDave J.Camera lighting makes the welds look really cold - looks better in personLooks like my camera thinks today is 2007  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've seen a lot worse 1st attempts. I think you recognize your problems, now all you need is lots of practice..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Practice is what was supposed to happen before I attempted thisI told my brother that practicing on the actual part is a no-no.  He just laughed and said do it anywayDave 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:doesnt look half bad man, especially your first time
Reply:Originally Posted by richTdoesnt look half bad man, especially your first time
Reply:Originally Posted by 7A7492007 Was a lousy year for me....... Yeah, for a first time, thy look pretty good. I've been doing some stick welding on a snow plow the last couple days. Amazing how fast you get rusty when you havent done it in awhile.Just keep practicing!
Reply:Ahhh I remember my first time...oh welding round tube that is. That is really good for your first attempt!Torchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:It looks great for a first attempt! What positions did you use for welding the coped pieces together? When I do it I tend to start with the piece laying on its side and weld my way up towards the outer edge of the coped piece (basically laying on the table the way you have it). I was also wondering if you welded the flange on before you welded the two main pieces together. Another little thing I have found works out pretty well for me is to use a makeshift manual positioner for all the possible flange welds. All it is is a piece of 12"X12" flat stock cut into a circle with a large bearing welded to it on center, with a piece of 1"x3" channel underneath to stabilize it. When I TIG weld on it I rotate the positioner with my filler metal hand and follow with my torch hand. It helps to create a single more consistent bead. Again, this is a fantastic first go at it, keep practicing!
Reply:Originally Posted by LivingstonIPresumeIt looks great for a first attempt! What positions did you use for welding the coped pieces together? When I do it I tend to start with the piece laying on its side and weld my way up towards the outer edge of the coped piece (basically laying on the table the way you have it). I was also wondering if you welded the flange on before you welded the two main pieces together. Another little thing I have found works out pretty well for me is to use a makeshift manual positioner for all the possible flange welds. All it is is a piece of 12"X12" flat stock cut into a circle with a large bearing welded to it on center, with a piece of 1"x3" channel underneath to stabilize it. When I TIG weld on it I rotate the positioner with my filler metal hand and follow with my torch hand. It helps to create a single more consistent bead. Again, this is a fantastic first go at it, keep practicing!
Reply:Originally Posted by GambleAhhh I remember my first time...oh welding round tube that is. That is really good for your first attempt!
Reply:I forgot to mention I used:   http://www.metalgeek.com/static/cope.pcgito cope the pipe.Since I did not find an option to cope inside of a 45 degree angle, I used a 67.5 degree cut angle, rotated the paper template and marked it on both sides.Website worked goodDave 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:Nice first attempt. You need to pressure test your whole set up before givig it real boost. Use soapy water in a spray bottle while under pressure. T.J.www.tjsperformance.comDynasty 300 DXHTP 240HTP Microcut 380Hyperthem 85JD2 Hyd Bender and HF Hyd Ring Roller all in one =(Frankenbender)Bpt. Mill/DRO4' x 8' CNC Plasma TableInstagram: tjsperformanceYT: TJS Welding and Fabrication
Reply:Originally Posted by MinnesotaDaveI forgot to mention I used:   http://www.metalgeek.com/static/cope.pcgito cope the pipe.Since I did not find an option to cope inside of a 45 degree angle, I used a 67.5 degree cut angle, rotated the paper template and marked it on both sides.Website worked goodDave J.
Reply:Originally Posted by TJSNice first attempt. You need to pressure test your whole set up before givig it real boost. Use soapy water in a spray bottle while under pressure. T.J.
Reply:Originally Posted by MinnesotaDaveHis system is getting pressure checked while on the dyno - I will post if the weld passed or failed Dave J.
Reply:Just thought I would update you on this project of MinnesotaDave (I'm his brother  )and TJS, no problems with leaks. Made 1260hp and 946ft/lbs.  the welds polished up nicely, and held 19lbs of boost
Reply:Dang!!How about a picture of what it's going in?
Reply:my '72 Chevelle
Reply:What kind of machine are you using? If it's a transformer try a green tung. It will ball up quick, and help wet out and give you a wider bead profile. Play with different tungs, theres a time and a place for all of them but get to know all of there charecters. Not bad tho, you'll only go up from now I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Um, I think you need bigger tires!I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Damn, have a big enough blower?How did you polish that aluminum so well? Or is it paint?Hobart 187 migLooking for tig
Reply:Originally Posted by weldermikeUm, I think you need bigger tires!
Reply:Originally Posted by djhenderlongDamn, have a big enough blower?How did you polish that aluminum so well? Or is it paint?
Reply:Originally Posted by melonheadthat angle makes the blower look huge. but don't get me wrong, it's a bad mofoas far as polishing. just takes time, good buffing wheels, a lot of compound, and dedication
Reply:Originally Posted by weldermikeWhat kind of machine are you using? If it's a transformer try a green tung. It will ball up quick, and help wet out and give you a wider bead profile. Play with different tungs, theres a time and a place for all of them but get to know all of there charecters. Not bad tho, you'll only go up from nowmusic is key, in a lot of shop work.
Reply:Update - For those of us that like to know what the finished motors sound like...Nick's motor on the dyno Now it just needs to find the engine bay of the car... Dave J.[ame]http://www.youtube.com/watch?v=yOSOgSpTqAw[/ame]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:That's a bad A$$ motor.And you can say "it's just a small block".TA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:more heat, or patience with the speed... Wait for the silver "lake" to appear then dip at the rate you edged fan out evenly at.  Not a bad first attempt.  Also clean the surface really well with a wire brush. The oxidation will cause difficulty in the cleaning and make for inconsistant bead edges.
Reply:Originally Posted by MinnesotaDaveUpdate - For those of us that like to know what the finished motors sound like...Nick's motor on the dyno Now it just needs to find the engine bay of the car... Dave J.
Reply:Skimmed through and didn't see it mentioned but what Blower is that an f2? And those Welds aren't bad at all for first time doing aluminum. Mike
Reply:Yep, I believe he's running an F2. Thanks, the thickness differences (1/8" to 1/16" and 1/16" to 1/4") plus going around the tubing made for a difficult learning curve.  But it'll get better the more I try it.  Hats off to the pros that make it look easy. Tig is a new process for me, but I definitely like it.  The control is so good I can easily see what mistake I've made - then practice to fix it.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:Originally Posted by killingmachineSkimmed through and didn't see it mentioned but what Blower is that an f2? And those Welds aren't bad at all for first time doing aluminum. Mike
Reply:Originally Posted by melonheadmy '72 Chevelle