Alum AC cobra kit car glove box

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One of our usual customers came down when he needed a few parts welded up, I said no problem.  The first was a butt weld on some 1/16 alum, at first I thought it was some sort of primary cover for a motorcycle, turns out it was the glove box for a kit car he was working on.  No pics of that butt weld, sorry.  The next time he brought down a few mounting brackets, hinge mounting bracket and the back plate.The next time he came down he had the dash panel that is going to be covered by vinyl.  It was 1/16 thick 6061 and he had a few aluminum screws he wanted welded to that.  The screws would hold the glove box to the dash, once the dash was covered there would be no way to get to the heads if the nylocks ever started to loosen up.  The screws were #6-32 and 1/2" long.  After looking at all the thin alum and scratching my head for a bit I got to work.Made a brass heatsink from some 1/2" hex stock we had laying around.  The weight of the bar was supported from below to keep it from pulling down and stretching the screw.SS wire brush and acetone clean for all of the parts and .035 mig wire I straightened out.Even with all the cleaning I did I needed about 35% DCEN to get a clean puddle.  Machine was set to 45 amps max, 5 backround, .9hz pulse and 150Hz  AC frequency for the screws.This pic shows the box welded to the plate which made the back of the glove box at the top of the pic, the hinge bracket welded to the glove box and the screws that were welded to the dash panel coming through the bracket.I had the machine around 60/15A and 25%DCEPAnother shot of the side of the glove box to the back plate.Those TIG fingers sure are nice for jobs like this.~Alex
Reply:Nice!  I keep around a collection of brass nuts for that exact purpose!