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gimpy2 Special user 960 Posts |
Been testing different methods to glue up a lap joint in 25 gauge aluminum.
I have sanded the joint with 220 grit ceaned with acetone then did the epoxy and let dry for twentyfour hours. Still think there may be a better way out there to get a stronger joint. Gimpy
Gimpy
www.gimpysmagic.com |
thegreatnippulini Inner circle of Hell because I've made 2582 Posts |
TIG welding. Can't be beat. TIG units are not cheap, and using them requires a lot of experience. In a pinch you could torch weld it with a cheap oxy/MAPP kit from Home Depot (about $60) and use aluma-weld sticks. The main headache about aluminum welding/brazing is that it has a very low melting temp (about 1500f) and a very high rate of conductivity. You may run into a lot of trial and error before getting it right. This is not an issue as the best way is to learn from this type of experience.
The Great Nippulini: body piercer, Guinness World Record holder, blacksmith and man with The World's Strongest Nipples! Does the WORLD care? We shall see...
http://www.greatnippulini.com |
EsnRedshirt Special user Newark, CA 895 Posts |
Yes, but welding technically isn't epoxy.
I've had some success with JB Weld. Just follow the directions on the tube. Note that it's absolutely useless for butt joints. And don't trust it to hold a person. Lacking a welding torch, I'd just bolt it together if it needed to support a lot of weight. Nippulini- I'm thinking about picking up a MIG welder eventually; do you know anything about the Millermatic ones with the auto settings? (Select type of metal and gauge, and it sets the voltage and rate itself.) If so, are they any good?
Self-proclaimed Jack-of-all-trades and google expert*.
* = Take any advice from this person with a grain of salt. |
gimpy2 Special user 960 Posts |
Yes I should add, Im just makeing a sqaure sleeve to slide over a 3" cube.
Thanks for all the help so far,I new you folks would know the best way to go. Gimpy
Gimpy
www.gimpysmagic.com |
thegreatnippulini Inner circle of Hell because I've made 2582 Posts |
I've never used those types of welders. I prefer to have more control over what I'm doing. Sometimes I utilize a lower heat on thicker steel for specific reasons. Comparatively it's like cars, some people prefer stick shift, others auto. Miller is a good name, I've used them in the past and had no problems. Avoid the temptation to buy a cheap welder (i.e. anything from Harbor Freight made in China).
The Great Nippulini: body piercer, Guinness World Record holder, blacksmith and man with The World's Strongest Nipples! Does the WORLD care? We shall see...
http://www.greatnippulini.com |
Bill Hegbli Eternal Order Fort Wayne, Indiana 22797 Posts |
Why not cut the whole strip out of the aluminum. Then bend the four sides, and have the lap joint met in the middle of the rear panel or side. No fold over the two ends and interlock. Tap with a leather mallet. You can then put any good glue made for aluminum in the overlap joints. Tap flush and let the glue dry. The you only have one seam at the rear.
25 gage seems a bit thick for a 3" square. I would reduce the gage. You might want to consider tin, it can be soldered by the flow method. |
Brett Sirrell Magician New user 77 Posts |
The problem is that alumium instantly forms an oxide layer as soon as the surface is revealed. Al is a highly reactive metal!! If it didn't have the oxide layer then we would have something very fun!
Anyway you have to bear in mind then you are glueing onto a metal oxide layer. Welding is difficult because of the oxide effect again. Hence you weld in a atmosphere of inert gas. I don't think you will get better than epoxy. I would go with a metal epoxy, prep the surface well. Maybe include a few microballoons in with the epoxy to give it crack resistance. Failing that how about pop rivets!
Brett Sirrell Magician and entertainer
www.brettsirrell.co.uk |
thegreatnippulini Inner circle of Hell because I've made 2582 Posts |
Welding Ti is even tougher, the oxide film stops anything from sticking. Titanium bike frames have to be welded in a hermetically sealed room pumped full of sheilding gasses (usually helium and argon). Ever price one of those things (the bikes)?
The Great Nippulini: body piercer, Guinness World Record holder, blacksmith and man with The World's Strongest Nipples! Does the WORLD care? We shall see...
http://www.greatnippulini.com |
gimpy2 Special user 960 Posts |
Ok, Heres what works.
Thanks to a the above help I was able to solve the problem. Made the sleeve out of one piece with a 5/8" lap joint in the back corner. What soved the probem was the comment about bare auminum being hard to bond to. So since the auminum Im working with has a factory finish,Its the same stuff gutters are made from. I didn't remove the paint I just ceaned it with acetone and applied the epoxy. The resut was a easy to make joint that will not fail.Aso the metal comes in black so I wont need to paint it. Thanks to all who heped me. Gimpy
Gimpy
www.gimpysmagic.com |
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