Newbie TIG on AL Piping. I Think I'm Getting It!

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So I took the feedback you guys gave me on my SS exhaust welds...did more practicing, and I'm finally getting some decent welds, but now on thinner AL intercooler piping.Here's the results so far:I did the bead in multiple sections as I don't have a proper positioner.  It still came out better than I expected and I don't mind the minor start/stop transitions.Any more suggestions?  I'm getting great feedback from you all.
Reply:Looking MUCH Better!DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Whoa, that's a huge improvement.  Nice job.What does the inside look like?Favorite right now is a Miller Syncro 200.Tons of tools and I blame at least one of them when things don't go right.
Reply:Very good!  That has to be very difficult!
Reply:Nice!   Doesn't aluminum seem actually kind of easy once you get the hang of it? It took a while for it to 'click' for me, but then seemed easy. Of course my beads don't look *quite* as nice as yours, good job !!- John
Reply:Definitely not so bad once you get the hang of it...but the learning curve is steep with no one to look over my shoulder in person.  Especially with the **** poor documentation of the Riland unit.But you guys have all been GREAT help.  Learned tons on this site.  Welding is almost therapeutic to me now.  Nothing but me, the arc, and the metal.  It's great fun.
Reply:Slow down the dips and carry on!!  Here's the big ?What does the inside look like??...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:The inside doesn't show much of anything other than the original joint.  There is ever so slight penetration here and there.Do I need more heat? When I start, the beads sits up higher and I have to give it a bit more.  As the piece warm up, the welds tend to flatten out and I have to let up more or risk burning through.What should I be seeing on the inside?  Full penetration?  My welds on the SS exhaust piping showed welds coming through.  Since this is lighter duty intercooler piping, I went a tad lighter on the heat so as not to risk burning through and ruin the welds cosmetically.
Reply:You won't "ruin the welds" cosmetically if you do happen to burn thru..But in this case you should keep that at bay as best you can..You don't want to have to die grind out bumps and spuckles inside for smooth air flow anyway..I've done a few intake manifolds with 2 piece runners..There is no burn thru to deal with..Keeps the engine builder happy...While its true it takes more heat at the start than at the finish..Thats what your footpedal is for..I'd set the heat @ 100 amps for what you are doing..Granted it may take a little longer to "get it going"..But by the time you go all the way around you'll be using only half the pedal power as it is...Looks great..  keep it up.....zap!Last edited by zapster; 07-10-2007 at 05:13 PM.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 TeCKis300The inside doesn't show much of anything other than the original joint.  There is ever so slight penetration here and there.What should I be seeing on the inside?  Full penetration?  My welds on the SS exhaust piping showed welds coming through.  Since this is lighter duty intercooler piping, I went a tad lighter on the heat so as not to risk burning through and ruin the welds cosmetically.
Reply:I was pulsing at about 110 amps. Yes, I was modulating the pedal and using less base amps towards the end of each weld.So I assume you are saying that nothing should really show on the inside right?  If that's the case, I'm happy to say the inside was near untouched with nothing to grind.  I'll get a picture up later.
Reply:And yes...I'm all about optimizing air flow for horsepower.  I port matching anything I can get at.  I even cut certain sections of the prefab SS exhaust so I could grind some nasty  joins at the flex pipe.
Reply:So I assume you are saying that nothing should really show on the inside right?
Reply:**sheesh ZAP posted AND edited while i was typing, and as to be expected was more helpfull to lol
Reply:Here's a pic of the inside.  The brown patch at the left was preexisting.
Reply:I never saw your first pics (I just joined this forum) but those are lookin good!"A winner isn't someone who doesn't lose, a winner is someone who doesn't quit."
Reply:i like the gloves keep your work clean .........keep it up!63' Lincoln SA200 2008 miller trailblazer 302fibre-metal pipelinermiller camo BWEand all the guns and ammo a growin boy needs