Welding unknown aluminum - help

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Hey folks,I'm trying to weld a 6061 aluminum bracket for a computer mount to the top handlebar clamp on my dirt bike. The bike is a KTM and I'm not really sure what the handlebar clamp top half is made out of. It looks as if it has some sort of coating on it. I'm sure the clamp is aluminum, not sure what grade.Any suggestions on prep to get a good weld. I'm pretty much new to tigging aluminum, but I do have the right rods and an assortment of tungstens and cups for my welder. I'm using a Everlast 200DX to weld it.Thanks in advance for any and all help.Wayne
Reply:As both a welder and a rider I would advise you not to weld on the bar clamp directly. I don't have a lot of aluminum experience but it will probably become more brittle even with an expert tig welder. The piece that you are trying to weld is probably cast, but could be machined from billet. Failure of the part could be very dangerous for you at the wrong time. Is there a reason that you don't want to bolt it to the handle bar mount, triple clamp, or handle bars directly. This isn't the kind of thing that I usually tell people but be careful.Ken
Reply:Ken,Thanks for the input and good advice. I think I am going to go ahead and make another top mount for the handlebar clamp. I've got lots of aluminum I can use to make it out of. Definitely would be safer. It would be easier to make the new mount out of 6061 and integrate the mount for the computer into the clamp.Thanks,WayneHobart 200 MVPEverlast 200DXEverlast PP50 PlasmaComplete Machine ShopToo many 2 wheelers
Reply:Originally Posted by riderdog... and integrate the mount for the computer into the clamp.
Reply:Originally Posted by KGIORAs both a welder and a rider I would advise you not to weld on the bar clamp directly. I don't have a lot of aluminum experience but it will probably become more brittle even with an expert tig welder. The piece that you are trying to weld is probably cast, but could be machined from billet. Failure of the part could be very dangerous for you at the wrong time. Is there a reason that you don't want to bolt it to the handle bar mount, triple clamp, or handle bars directly. This isn't the kind of thing that I usually tell people but be careful.Ken
Reply:That sounds like a much better plan Wayne. Maybe you can post up some pics after its all done.Thank you Donald.