Welding aluminum

[AirPower]

Can anyone help with this - what do I need to weld aluminum, like pipes and manifolds ect.

I don't mean only the case, but mostly pipe - I'll soon need to start fabricating intake ducting to the carbs + carb hats.
Is it possible to weld these with a torch? I'm hoping to avoid TIG or MIG welding - I'm not going to buy one of those because they are probably very expensive. Does one get alu rods for use in a arc welder? (Shows how little I know about welding).

The best solution would be cheap and a shop to get it from.

Thanks guys.
Mario

[BUGGOFF]

As i understand it is possible to arc weld alu. U can buy the rods at any hardware. All u need to do is swop the electrode with the earth. In other words u weld with the earth. Did the research, but never tried it.

[eben]

http://www.durafix.co.za/

[BARON]

Do a search on "advice" section,we have discussed it a bit here before.
But know this;- 1)There is a difference between Magnesium ---engine block-- and aliminum .
2)Magnesium burns like fibre glass and doesnt stop ---so be carefull ,but alliminum is ok to weld. 3) With electric welding you need D/C current
4) Oxy accetelene process is easy to learn
Aliminum does not show you when its at melting point ( it actually shows you but you must be very sharp to see it) so by the time you think it ready to weld its to late-everything falls on the ground- So its practise --practice --practise.
You can also go to http://www.metalmeet.com for more welding info I think its in the " joining metals" section.
cheers
Baron

[AirPower]

Thanks people! I'm going to give the Durafix guys a ring - looks like something I could use.

[Replica]

Just a word of caution, be careful with welding aluminium and its alloys. Many years ago I welded up an aluminium sump that was cracked using arc-welder with ally rods. When I finished, welds looked perfect. Half an hour later when I looked at it, it had many more cracks than when I started. Apparently it cooled down too fast (did not know that I was supposed to control the cooling). Never tried it again.

[ZeroAxe]

Well, actually to properly weld aluminium you have to pre-heat it(cant remember the temperature), weld it, and do a controlled cool down. In other words, have it in your heating 'oven' and slowly turn down the heat. Otherwise it will crack like you say. I have tried to weld aluminium before with a TIG, and it is EXTREMELY frustrating. Because if you dont have proper training/experience, you tend to burn more holes than weld....

[AirPower]

Now you guys have me worried. Maybe I need to go for stainless pipes etc. I would use PVC, but it won't stand the heat.

yeh, stainless... maybe

[eben]

Airpower, with the product i showed you you need to get the SURFACE of the think you are welding to just over 300 degrees with a flame ... scratch the surface to make the weld and it cools down in 30 seconds. Watch the video.... electric welding on alum. is a bit more risky/involved.