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Here's another aluminum repair job.I buffed the paint off from around where I was going to weld, then I tacked the two pieces back together without prepping the faces so I could get an exact fit.  Then I welded the underside, running pretty hot so get some good penetration.  On the other side, I ground a notch back to my first weld so I could get a full pen weld.  I first ran the tig torch along the groove without filler to see if I had made it all the way to my weld.  I found a couple of spots that didnt go deep enough and fixed it at that point.  Then I started running passes until it was all fixed up.  After all that, I went back to the inside and ground my weld back off.It took me about 45 minutes by the time I had it back together again. Attached ImagesCommon sense in an uncommon degree is what the world calls wisdom.
Reply:Cool Repair !  That would have cost a lot of money to replace such an old machine...with a new one.Did you use 4043 for that repair ?  1/8" tungsten ?  Amperage ?GREAT looking welds BTW,Cheers,/Jman...Miller Diversion 165120 amp Buzz BoxVictor Oxy/Ace Oxy/LPGSmith "Little" Oxy/LPGHypertherm Powermax 30Lot's of Misc. tools n' crap....
Reply:3/32 green, over 200 amps with my dig all the way up and 4043 as the filler.  I was too lazy to swap out the tungsten for 1/8" so I just turned my dig up.Common sense in an uncommon degree is what the world calls wisdom.
Reply:nice job what kind of tig welderdo you have