Looking to weld some aluminum

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Hello all, my first post!Heres the deal, this spring/summer we want to redo our duck blind on our jon boat. I welded up one last summer using 1/2 and 3/4 square steel tubing but after doing more research online and looking at other boats I want to redo it and make it out of aluminum/change the structure of it. Currently i have just a handy little Lincoln 125HD but I was thinking about going to a Hobart 140. I have taken a college course in welding and for the amount that I weld am pretty decent, I know aluminum is a whole different ball game but i was able to do a little bit of TIG work in that class, of course though that was a expensive machine.So basically what I am looking for is something that i can weld 6063 aluminum with. The new frame would be 3/4 and 1" square tubing with a thickness of .065. I know the best option is to get an more expensive machine but a) i cant afford it and b) dont weld enough to make it worthwhile to invest in a bigger/better machine. My idea was to get the Hobart 140 and retrofit it to make it work with a spoolgun but I wanted some opinions from everyone first to see if there was anything better/other options.I know that setup will not make perfect welds but I really just need the structure to stay together, i couldnt care less what the welds looked like.Thanks for any and all help and suggestions!
Reply:The HH140 with spool mate 100 is defiantly doable...A small 165-185amp AC tig might be a more versatile choice tho.Just a couple welders, big hammers, grinders, and torches.Work will free you.Men in dirty jeans built this country, while men in clean suits have destroyed it. Trump/Carson 2016-2024
Reply:Alum mig is a hot process. You max out a 220v 180 amp class mig doing 1/8" alum. 1/16" alum is doable if you max out a 140 amp mig, but your working window will be very narrow. Get hot enough to get good penetration and you will be very close to blowing holes in the material. Turn it down, and you will be too cold for good penetration.Alum mig is also a very fast process. You need to move probably 3 to 4 times faster than when doing steel. That makes short welds on small tubing a PITA, especially if you try to weld around corners with a bulky spoolgun.Keep in mind alum mig uses 100% argon, not standard mig mix used for steel. You can't use one gas for both materials. You'll either need to throw away any left over gas when you want to switch, or look at buying 2 cylinders.This is doable, but I wonder if the cost will give you the results you really want. You might be better off making it from steel using a different design to save weight ( the reason I assume you want to use alum), use mechanical fasteners and gussets rather than welds or simply pay someone to do it for you..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:thanks for the responses, I knew i was going to have to run with 100% argon I just forgot to put that in there. I actually do not have the Lincoln set up to run gas either. I would love to be able to retrofit that one to avoid selling and buying a new one.Anyway like I said it is only going to be .065 thick so nothing extreme but it sounds like even at that thickness that the HH140 might not work? and i have thought about doing the entire thing in 1/2" steel tubing but I probably pick up a little more weight and 1/2" might not be the best to construct a whole frame out of?
Reply:Originally Posted by th3godf4th3rAnyway like I said it is only going to be .065 thick so nothing extreme but it sounds like even at that thickness that the HH140 might not work?
Reply:ok well heres another question that may be stupid, could I use my 125HD with this http://shop.oxarc.com/lincoln-electr...model-welders/and the K2526-1 Lincoln Electric Mig Conversion Kit? or is the 125 just not powerful enough even if i did do that to go through the hassle
Reply:I personally think it's gonna be an exercise in frustration.  Thin wall aluminum tubing with mig is very difficult.  Aluminum mig is for thick stuff.  It's spray transfer.  Unless you have a very sophisticated setup, like a XMT with a Optima module for fast pulse , it ain't gonna happen.Sorry to rain on your parade.  What's your location?  Maybe someone will help you out.  I was duck hunting on thanksgiving on Long Island Sound.  If you're close, I'd be glad to help you out.TA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:Originally Posted by DSW1/16" alum is doable if you max out a 140 amp mig, but your working window will be very narrow. This is doable, but I wonder if the cost will give you the results you really want.
Reply:If you are building this boat because you enjoy welding, I think you will find TIG more rewarding and enjoyable. Also the end result will be more aesthetically pleasing than a cheap Spoolgun weld.   I am impressed with the AHP200x so far that I have.  It's probably one of the least expensive AC TIG machines that are available new.  If you don't need portability,  an old AC/DC transformer welder bought on the used market will serve you well.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:thanks guys, well that AHP200x looks good. Still not exactly what i wanted to spend but I will sell the little 125 and save up a little bit for that. I dont plan on working on this until spring/summer anyway. The next problem i face is finding someplace that has a 230v outlet!and not building a whole boat, we already have a 18' lowe jon boat, just making a aluminum frame and then going to cover it with some aluminum flashing then camo
Reply:Originally Posted by th3godf4th3rthanks guys, well that AHP200x looks good. Still not exactly what i wanted to spend but I will sell the little 125 and save up a little bit for that. I dont plan on working on this until spring/summer anyway. The next problem i face is finding someplace that has a 230v outlet!and not building a whole boat, we already have a 18' lowe jon boat, just making a aluminum frame and then going to cover it with some aluminum flashing then camo