aluminum joining

[taintedplay]

I am thinking of joining two aluminum cases together side by side. My only question is, What would be the best way? i cant solder becuase its aluminum, so how would i do it?

[Eclecticos]

Alumaloy (http://www.cisoldit4u.com/alumaloy.htm) and MAPP gas, or a MIG Welder.

If you choose the Alumaloy route here is the basic instruction.

http://img208.imageshack.us/img208/3612/piktoriaio3.gifhttp://img164.imageshack.us/img164/4572/piktorialpu1.gifhttp://img179.imageshack.us/img179/5165/piktorialsmg3.gif

[blueonblack]

Wow, that is some very cool stuff! +rep
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[taintedplay]

would te mapp gas and alumaloy when finished look good? or would it be an ugly but joined weld

[calumc]

There were brazing rods for aluminium posted here a while back, have a search for them.
But for aluminium i would try to stick with mechanicial joining methods if at all possible.

[jbaldwinroberts]

Drill some holes in the side of both cases and either rivet or bolt them together.

[Eclecticos]

would te mapp gas and alumaloy when finished look good? or would it be an ugly but joined weld

Sure, if you do it right.
I would c-clamp the cases together and fill in the crease, then dremel with a sanding drum . .until the desired finish is achieved. Its actually a type of brazing. You may want to check the tips and tutorials section for more info.

[Eclecticos]

Or you could get yourself a nice MIG welder, and start practicing.
You can pick on up for as cheap as $195.00

http://img183.imageshack.us/img183/6831/millermigqi5.jpg

[calumc]

Ive never actually done it but from what ive heard welding alu isnt for n00bs, and another point to note is that cheap MIG welders probably wont be capable of welding aluminium (current needs to be AC rather then DC for steel)

[Eclecticos]

Ive never actually done it but from what ive heard welding alu isnt for n00bs

I agree, from what iv'e heard mostly on tv welding aluminum is no easy task.
You know what they say practice makes perfect.
Id recommend practicing on allot of scraps first if you want it to look nice.

Im 100% sure the Alumaloy will create a strong bond between the two cases.
You may want to make sure it is aluminum and not SECC you can check it with a magnet.

[Bopher]

Ive never actually done it but from what ive heard welding alu isnt for n00bs

Yeah, Aluminium is very hard to weld for some people. I've done it a few times and each time I have 1 little spot I've burned through. Very easy to do with alu and stainless steel. But sometimes if you tack first then keep everything in short shots and not to long on the mat you can get a decent bead.

[crazybillybob]

You can always go the other route and just rivet the two together. Most cases out there are already put together with the little fasteners already :) If you choose the placement and size correctly you'll get a strong bond that's way easier then welding. Rivets are also cheaper even if you have to go out and buy the equipment to install them, plus every modder should have their own rivet gun!!!


BillyBob

[Bopher]

plus every modder should have their own rivet gun!!!

BillyBob

Crap, I knew I was missing something! But yeah rivets are easier to use and the stuff is cheaper to buy. I had a truck topper we fixed the door with rivets and it held together for a long time.

[Omega]

yeah

I ALWAYS have a rivet gun and 1/8 steel & alu rivets in my shop.

[Eclecticos]

I found this picture.
"Project : SINISTER DEXTER"

http://img381.imageshack.us/img381/3513/31806318sk0.jpg

May be a better method of joining the cases.