I've got a tranny housing for a motorcyclce project that I am working on. There is a small section that the PO had repaired a crack. It's pretty ugly. Anyway, I wanted to add more meat, so I can grind off and make it look better.

I'm considering stick welding some aluminum (and the most cost effect for my needs) There aren't too many discussion (or value-added discussions) on the net. Most participants of these discussions are quite negative about the idea. Anyway, I found a site that shown some promise. But he doesn't go into detail on how he improved his welds. Maybe it was just more practice.

http://www.hildstrom.com/projects/stickaluminum/

I may want to take more similar projects in the future.
Anyway, do you guys have any advice?

Thanks.

 

I have done more than I'd like to admit to. Mostly repairs on transport rail cars.
At first the results were functional, then they got prettier. It's not the easiest, but isn't really any harder than a spool gun if you have some decent SMAW experience under your belt.

 

ive just got some alloycoverd rods , ill let you know how i get on

 

Sure, if thats all you have access to. Definitely practice a LOT before you do anything mission critical.

 

thanks for all your inputs guys...

pleej, what brand sticks are you using?

 

When I was 15, I welded an entire aluminum boat trailer together using a dinosaur of an arc welder. I practiced on some scrap for 3-4 hours and went at it. Its ugly at first but youll get the hang of it. That trailer is still together 13 years later hauling a 20+ ft boat. My tip is go hot and go fast and make sure you bevel your weld joints.

 

I recall someone posting about oxy welding aluminum. Apparently some company has really put lots of effort into designing a new torch, and their promo vids show it working like butter.

For a small spot, I'd almost suggest biting the bullet and getting a pro to TIG it.