I have been using that front panel as a test section, and in order to prepare it I have drilled out the end of any cracks with a 1/32 bit. This is to stop the crack from getting any worse.
Once the cracks were all treated and the panel had all paint removed I tried out Alumiweld as a first go. The process to get the solder to melt into the crack is a bit tricky. After a few attempts I had some luck, but it doesn't hold up to any sort of flex in the panel.
Props to all the welders out there who can get TIG to work properly. I spent 3 days in my friends garage working with his ESAB and I just couldnt get it to work properly. I ran down to the local welding shop, got all kinds of advice, tried different tips and rod, changed out the gas. However, I just couldn't get it right. Couple that with the fact my friend lives completely across town, and this welder requires 220 (which I dont have) I had to try something else.
The results of some TIG practice. I think now, my problem may have been not enough shielding gas, but maybe someone with some more experience could tell me just by looking at the welds in the pic.
I have a 135amp MIG at home that you can buy an aluminum spool gun for, so that is the next plan, buy the spool gun and give it a go. After purchasing some pure Argon for my welder and messing about with the gas settings I managed to get my first decent weld on the Birmabright. I realize the picture below doesnt look like much but the weld is solid, and it has penetrated both panels. Although small, I consider this a victory.
The problem with my shop is that 20amps is the largest circuit I have, and I cant put anything more in there, 220 is unavailable in my unit. So I have had to work around that, and I think I have settled on a good solution.
One of the issues with welding aluminum is the gases and byproducts that it releases when welding. So I built myself a small fume hood with a bathroom fan and some flexible ducting. It actually works pretty good for the welding, and just about everything else, so I have been using it pretty consistently.
