1/16" aluminum plate to 3/8" aluminum bar...HOW?

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Hey guys,Any suggestions on welding 1/16" plate to 3/8" bar (aluminum).  With Tig.  I was thinking of cutting little wedges from the bar to use to fill the gap between round and flat surface. Only need little random welds. Nothing to structural more like a sign project.Thanks for any suggestions or ideas,The Tig Kid
Reply:Give us more info on what you are trying to do. Pictures help also.Airco Ac/Dc 300 HeliwelderMillerMatic 200 (stolen)Miller Maxstar 150STLMiller AEAD200LE (welding and generating power) Hobart MIG
Reply:Strike arc on 3/8" bar, and wash the puddle onto the 1/16 plate.
Reply:The position you weld in madness a big difference tooSent from my SCH-I545 using TapatalkTiger 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:Originally Posted by SquirmyPugGive us more info on what you are trying to do. Pictures help also.
Reply:Hi -  I did a lot of these lugs. I used 150 amps, 3 mm 4043 filler and as mentioned start arc on rod, drag puddle towards plate and dab when puddle is about to touch plate. Not the filler rod - Arc start on rod to be welded to plateLast edited by Odd Job Welding; 02-26-2014 at 12:45 AM.
Reply:The-Tig-KidNot enough info  -  show us the joint.Opus
Reply:Drill holes in 1/16 where you want attached and plug weld to bar, then grind flat.  As OPUS says, show pic.TA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:I'm with 255 on this one. fast, clean and no screwing around........altho 6/32 stainless screws would work too.Bubble gumTooth pixDuct tapeBlack glueGBMF hammerScrew gun --bad battery (see above)
Reply:I did 1/2" rigid 3063 conduit to 1/4" x 3" flat 6061. I had best luck using 1/4" round in the joint.
Reply:Originally Posted by Odd Job WeldingHi -  I did a lot of these lugs. I used 150 amps, 3 mm 4043 filler and as mentioned start arc on rod, drag puddle towards plate and dab when puddle is about to touch plate. Not the filler rod - Arc start on rod to be welded to plate
Reply:Focus the heat on the 3/8 and wash into the 1/16 should work for ya.