Why not buy the spool gun?

 

"Although I won't be welding for a living, I plan to have a hobby metal shop for my retirement where I envision welding 3/8" thick aluminum and sometimes 1/2" or larger."

What the hell sort of 'hobby welding' do you plan using 3/8-1/2" or thicker AL? And, it looks like CEP is 'cheating' by demonstrating the use of 4043! One HAS to suck lung fulls of 5356 smut.....

 

Isn't bigger always better? Who knows what type of welding I'll be doing in the future, but I should note that I have a small farm, a sawmill operation, and various pieces of heavy equipment (stock trailers, tractors, backhoe, a couple big trucks). I'm an engineer by trade so who knows what hair-brain fabricating idea's will come out of my noggin in the future.

A couple of weeks ago, I rented a somewhat low aluminum trailer to pull behind my jeep so I could haul home an 800 lb wood boiler . I chained the winch to the side pockets (something like 3/16 or 1/4" thick) on the AL trailer. While winching the boiler up the incline, the aluminum pockets on the side of the trailer started to bend. I learned that although aluminum is light, it isn't very strong.

 

Spool gun or try to find a cobramatic feeder with a push pull that's your best bet

 

I have VERY little experience with MIG aluminum. I have owned a spool gun for my Millermatic 252 since 2013. I haven't had occasion to plug it in.

When I explored the concept of aluminum welding, a salesman convinced me to buy a spool gun. He demonstrated. It was OK, not impressive.

Before that, I asked a friend who had bought an outfit if I could try his. He bought his to build custom truck beds. He sort of built one. I tried on 16 gauge alum. to build a simple box. I keep that mess around to show how far I have come.

Now you want to see me get excited about aluminum welding, lets talk TIG.

I believe MIG should be used for 1/8" thick, and greater. TIG is good for all thicknesses.

 

That's a Very nice system. If it was Pulse it would be golden. That was one of the best Lincoln units. You can find a spoolgun for it for not much money and get started there. Many many options as you move up in equipment from there.

 

I have few questions. Does the operator manual have any parameters for welding alum?

Are you open for using 5356 filler 3/64" diameter(which is what I use for heavy plate 6061-t6 and feeds wonderfully)?

If it were me I would start with U groove drive rolls and a short torch and nylon liner. See if it even starts and maintains an arc.