Pool Ladder Grabrail TIG Repair

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Well I took on my first aluminum TIG job for the 180 SD today which wouldn't have been any big deal for many TIG'ers but basically being my first aluminium TIG experience and based on what I was working with I consider myself fortunate to actually get through it.The subject was a pool ladder grabrail that broke where one of the supports bolts to it and was not only broken in two but somehow suffered two splits aproximately 1-1/2" long along the centerline of the rail in each direction from the bolt hole on one side.  The item belongs to someone one of the guys at work knows and I offered to do it 'for the experience' when someone suggested I do it.Hardest part was getting the pieces cleaned up inside and out as they were pretty nasty with corrosion and dirt.  It wasn't pretty as it require a fair amount of building up missing material and closing up one of the splits was a bit of a challenge for me.  I believe it would have gone a little better if I had a 1/16" tungsten but 3/32" is all I have at the moment.Seven photos so please wait for the second post and here are the details:1" diameter ribbed aluminum tubing - 1/16" between ribs, 3/32" thick ribs3/32" pure tungsten (green) balled tip1/8" 4043 filler (big I know but only size 4043 I have)Argon @ 12cfhAC w/ balance set for maximum cleaningCurrent control set for 50amps maximumK-LOVE playing on the radioThis is how it started.  I forgot to take a shot of the other side that had the bulging splits although you can see part of one on the piece on the right.Sorry about the fuzzy shot - radial weld with bulging splits tapped back in place with brass hammer and welded up.Bolt hole area built up where material was missing.  I warned you that is wasn't pretty!Opposite hole following welding and ground smooth for appearance and proper fastener seating.Built-up hole area ground to proper contour for grabrail support to fit.Please stand by for two more photos.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Post #2Head side of grabrail support machine screw.Next challenge is coming up with a replacement threaded aluminum 'anchor' insert to TIG in to make the support on the left look like the one on the right.Thanks for looking and I welcome any critiques and suggestions.DuaneMM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:looks good.  hard to repair old, thin alu when its not all there.with the limited tools i have, i would get and engineer friend to machine up some solid bar to fit I.D. (about $35)  and leave enough out for me to grind and file the curved shape.
Reply:wow duane, given the rod and tungsten sizes that had to be a challenge what is the wall thickness?250DXMM251MM175225G plus 251D-1
Reply:Aw, just skip the threaded insert and cope-n-weld the rung/support on.  How are you going to re-flute the tube?        The best laid schemes ... Gang oft agley ...
Reply:don't care what you say, thats some pretty good welding
Reply:duanne it turned out pretty darn goodLincoln 255XT Power Mig                                                                    Lincoln Precision Tig 225Hypertherm Powermax 30
Reply:Originally Posted by duaneb55Which wouldn't have been any big deal for many TIG'ers but basically being my first aluminium TIG experience and based on what I was working with I consider myself fortunate to actually get through it.
Reply:Originally Posted by LarryOlooks good.  hard to repair old, thin alu when its not all there.
Reply:Originally Posted by duaneb55Thanks LarryO.  It sure tested my current abilities.It certainly was for me.  Makes me believe I should be thinking about picking up some smaller tungsten and smaller 4043 filler rods.