Anyone brave enough to take this on for me?

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Rear trunk handle for a BMW motorcycle...cast aluminum. I currently only have DC tig ability... I thought about giving the spoolgun a go...  but my gut says no. I think tig is the way to go. (on the bright side, its a clean break and a non oily, non dirty piece. ) If you can help or have a suggestion, shoot me a PM. thanks.  Miller 211Hypertherm PM 451961 Lincoln Idealarc 250HTP 221  True Wisdom only comes from Pain.
Reply:Originally Posted by John TRear trunk handle for a BMW motorcycle...cast aluminum. I currently only have DC tig ability... I thought about giving the spoolgun a go...  but my gut says no. I think tig is the way to go. (on the bright side, its a clean break and a non oily, non dirty piece. ) If you can help or have a suggestion, shoot me a PM. thanks.
Reply:Originally Posted by WNY_TomB..i would recommend a torch and alumiweld or a aluminum solder. most important is do not assume it is aluminum. it could be a zinc die casting. i could be wrong but i think safer to try solder
Reply:additional pics...Miller 211Hypertherm PM 451961 Lincoln Idealarc 250HTP 221  True Wisdom only comes from Pain.
Reply:Too bad you don't live near me - I'd let you come out and use the machine 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:If you have AC aluminum tig experience, you can practice on some scrap using a 1/8" tungsten and go DC+ with argon.Your piece is so small, an 1/8" tungsten would survive long enough to get it done.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:I'd do it for you but I don't think you are local to meTorchmate 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:you obviously can do with dc tig if you use aluminum stick rod flux and all as dc tig filler rod. the flux can be hard to remove some use hot water and a wire brush. not sure if you could just do in the kitchen sink.if you got 150 amps you should be able to do 1/4" aluminum or thinner without preheat or helium. just use argon and straight polarity. you could buy some flux in a container but easier to use aluminum stick rod which is flux coated.
Reply:Originally Posted by MinnesotaDaveToo bad you don't live near me - I'd let you come out and use the machine
Reply:Originally Posted by WNY_TomByou obviously can do with dc tig if you use aluminum stick rod flux and all as dc tig filler rod. the flux can be hard to remove some use hot water and a wire brush. not sure if you could just do in the kitchen sink.if you got 150 amps you should be able to do 1/4" aluminum or thinner without preheat or helium. just use argon and straight polarity. you could buy some flux in a container but easier to use aluminum stick rod which is flux coated.
Reply:Originally Posted by MinnesotaDaveIf you have AC aluminum tig experience, you can practice on some scrap using a 1/8" tungsten and go DC+ with argon.Your piece is so small, an 1/8" tungsten would survive long enough to get it done.
Reply:oops...just read your other reply..Miller 211Hypertherm PM 451961 Lincoln Idealarc 250HTP 221  True Wisdom only comes from Pain.
Reply:I should say, The only tig I have is a scratch start idealarc in my sig line.Miller 211Hypertherm PM 451961 Lincoln Idealarc 250HTP 221  True Wisdom only comes from Pain.
Reply:If you practice on some other cast AL you could stick that back together. The 1/8 tungsten can't handle more then about 80 amps if I remember right
Reply:Just as discussion..Do you think spoolgun is a Bad idea? or is it possible to get it done with that method also?Miller 211Hypertherm PM 451961 Lincoln Idealarc 250HTP 221  True Wisdom only comes from Pain.
Reply:Originally Posted by John TI should say, The only tig I have is a scratch start idealarc in my sig line.
Reply:Definitely not a fun way to learn. If you have some scrap aluminum the same thickness (sheet alu would be fine, doesn't have to be cast) then I'd have a go at it with the spool gun.
Reply:John you are welcome to bring it here. I am not sure my TIG skills are up to the task, but I am willing to give it a shot, or let you take the helm. I have 4043 filler. If you want something different, you would have to get it first. I am only 20 mins from your house.Miller Multimatic 255
Reply:I would find someone to Tig it. That small of piece and a spool gun = badMillermatic 252millermatic 175miller 300 Thunderboltlincoln ranger 250smith torcheslots of bfh'sIf it dont fit get a bigger hammer
Reply:I have the equipment to TIG it, and live close by to John. Just not sure I have the requisite skills.Miller Multimatic 255
Reply:Originally Posted by motolife313If you practice on some other cast AL you could stick that back together. The 1/8 tungsten can't handle more then about 80 amps if I remember right
Reply:I'm taking about DC+. He doesn't have a machine with AC
Reply:I think that would weld nicely with AC TIG. Being a BMW part, it's probably some high-quality aluminum. The main reason for welding it would be the price of a replacement part. I can't imagine what it would cost.Miller Millermatic 252Miller Syncrowave 200Liincoln AC-DC 225Victor O-A Set
Reply:Originally Posted by mcostello80 amps with 1/8" tungsten? Running 190 with 3/32, must be doing something wrong.
Reply:I'll do it.WillieAn optimist is usually wrong, and when the unexpected happens is unprepared. A pessimist is usually right, when wrong, is delighted, and well prepared.Originally Posted by John TJust as discussion..Do you think spoolgun is a Bad idea? or is it possible to get it done with that method also?
Reply:Originally Posted by Willie BThe post must be a misprint. I've run 280with 1/8 and would use more if I had it.
Reply:Originally Posted by Willie BThe post must be a misprint. I've run 280with 1/8 and would use more if I had it.
Reply:Not all charts list DC+ (DC reverse) but check this one out:Higher amps will still work for short durations.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 MinnesotaDaveNot all charts list DC+ (DC reverse) but check this one out:Higher amps will still work for short durations.
Reply:I don't know what the hell the big deal is anyhow...10 min.Done....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:Wow,  I can't imagine what that piece would look like if welded with DC+. It's  so thin, it really needs AC with high freq. and low amps to start. Knowing what I know about motorcycles, I'm guessing that's a $300 to $400 part so it has to be done with the proper process. Just my opinion but I've only owned 40 motorcycles or so.Miller Millermatic 252Miller Syncrowave 200Liincoln AC-DC 225Victor O-A Set
Reply:Willie has me covered. Sent from my iPhone using TapatalkMiller 211Hypertherm PM 451961 Lincoln Idealarc 250HTP 221  True Wisdom only comes from Pain.
Reply:Originally Posted by gnm109Wow,  I can't imagine what that piece would look like if welded with DC+. It's  so thin, it really needs AC with high freq. and low amps to start. Knowing what I know about motorcycles, I'm guessing that's a $300 to $400 part so it has to be done with the proper process. Just my opinion but I've only owned 40 motorcycles or so.
Reply:Originally Posted by zapsterI don't know what the hell the big deal is anyhow...10 min.Done....zap!
Reply:lincoln welding book shows thin aluminum being welded with a simple carbon in electrode holder and using aluminum stick rod flux and all as filler metal. my book is from 1981..you technically need no tig but if you have a tig i would use it on straight polarity. this is what is taught to apprentice welders that you can weld aluminum with a simple carbon arc and using flux covered rod. nobody says it is the best way. just what is taught if you got occasional jobs.sure go spend money buying expensive welding equipment but you do not have too. sure flux is not the easiest to remove but chip off the big stuff and use hot water and wire brush is what i have always used. spec says stick rod but can be used as torch brazing alloy. it reality torch can be tig torch, carbon arc torch, oxyacetylene torch.common rod specs All position aluminum electrode for welding aluminum and aluminum alloysOperates at low temperatures with a stable arcMinimal spatter and fumingCan also be used as a torch brazing alloyApplications include truck beds, loading ramps, docks, diamond plate, irrigation piping, engine blocks, transmission housing, etc...Last edited by WNY_TomB; 02-15-2016 at 01:13 PM.
Reply:Just for schits and giggles I have tried DC and argon on aluminum.....do-able but not good.DC and helium you could weld that part with .020 tungsten.To me that part needs AC and argon.
Reply:I tried with the Dialarc DC electrode pos. on aluminum. It worked well on very thin metal with a big tungsten. DCEN Wasn't as bad as you might expect. The aluminum seemed to form a skin, It was necessary to push filler hard under the skin. I believe it was a somewhat sound weld, with an ugly surface. It then wire brushed clean, but not looking like something Zap had done. I think it's BC who does DCEN with Helium, his work is always pretty. I might add a bit of helium, but it isn't needed to melt, AC is best.An optimist is usually wrong, and when the unexpected happens is unprepared. A pessimist is usually right, when wrong, is delighted, and well prepared.
Reply:Piece of cake, are you close
Reply:Where are you. Bring it. We can do it. 4943 fillerwww.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 zapsterI don't know what the hell the big deal is anyhow...10 min.Done....zap!
Reply:John you can come use my syncrowave if you want.  Only 5 minutes away.
Reply:Thanks TJ , Brendon and others...But As of this morning, its headed priority to Willie. Sent from my iPhone using TapatalkMiller 211Hypertherm PM 451961 Lincoln Idealarc 250HTP 221  True Wisdom only comes from Pain.
Reply:Its here if you ever need to weld alum!
Reply:Originally Posted by brendonvIts here if you ever need to weld alum!
Reply:Haha. Thanks!  I always try to beep when your wrenching. But really, dont be shy. The syncrowave 250 and miller 252 are always ready to play!