Mig Aluminium Welding

[wracing 19]

While its the general consensus that most varieties of a do it your self throttle body system isn't worth the time and the money, and ends up been more of a pain in the arse than a performance improvement.

 

I've tried the silicone joiners route and ended up getting so pissed with having to rebalance even though I braced the bodies to the block!

 

I don't have a TIG any more so I needed a solution.

 

Aluminium welding with MIG.....

 

It requires some degree of experimentation but it can produce some really good results.

 

 

So the welder I'm using is a 3 phase 350 amp kemppi with a separate feed unit. While its not necessary to have such a large current rating, what is important is to have good control on the wire feed.

 

Pure argon must be used and as a filler wire bostrand 286 which is available in all drum sizes at a low cost.

 

 

You must make sure the aluminium is really clean and if possible use a new stainless steel wire brush.

 

This was my first attempt and you can see there is no penetration (110amps and 4m/m wire feed )

 

 

More current got the penetration but needed to up the filler wire to match.

 

 

Sorted at around 180amp and 8m/m wire feed.

 

While you can get a nice looking weld when butt welding with gravity helping you, I found the alloy quickly ran into a ball at the end for the weld. You just have to make sure that you move the work piece so gravity is helping you

 

The great thing with aluminium is that if you make a mistake you can remelt it

 

 

You can see the small bits that require dressing off, that said there is still a nice strong weld there.

 

 

Not as neat as TIG but very cheap cost effective way

 

I wouldn't weld brackets for things like suspension components but its great for all these little jobs that a DIY'er would normally have to outsource.

 

Thanks

 

James

Edited July 16, 2010 by wracing

[pugpete1108 62 1 Cars]

you seem to be a really handy fellow to know

 

i need to speak to you about having a manifold fabbed up in the future.

[All Praise The GTI 3]

very creative mate

[wracing 19]

What a turbo manifold??

 

All Praise The GTI i've been trying to get hold of you, do you get your cage sorted or do you still need a hand, the number you pm'ed me doesn't work

 

 

James

[pugpete1108 62 1 Cars]

yeah, either that or a custom inlet so i can bolt on a supercharger

 

i cant really decide? we can have a chat when i come up

[wracing 19]

All finished and fitted to the car total cost 325 pounds including all the parts manifold injectors fuel rails.....

 

 

 

James

[All Praise The GTI 3]

looking good.

yes desperatley need cage doing asap really pm on its way mate