I've been doing a lot of intercooler piping work and such as of late, and I've been having a really hard time finding a good, relatively quick, and reliable way to clamp aluminum pipe so I can tack it together. I HAVE been using a c-clamp, and while it gets the job done it's just an awful way of doing things. It marrs up the finish and rarely gives me a good fit.

I have an idea for a bar that can hinge and has two sliding clamps on it to be able to clamp pipe in the many different directions that the IC piping can go, but I wanted to see if anyone had any good advice before I go scrap a bunch of metal trying to figure this out.

 

man, i've been having a hell of a time doing the same thing, that bar with sliding clamps sounds like a pretty sweet idea!

 

I have yet to make one of these, but it is on the to do list. Make it out of aluminum so you don't scratch your material.

 

Not my picture but heres one CHEAP and easy way. you can also drill a hole in a pipe, split it, then hose clamp it on.
or maybe even hose clamp on two pieces of angle iron.




few other ways from google
http://farm3.static.flickr.com/2765/...7d4ba682d3.jpg

 

That's an amazing idea. I can see how putting a piece of rubber inside that clamp would help keeping the surface free of scratches from the clamp also.

I also like these to hold the piping at weird angles while i weld and also helps so I don't touch if after i weld.

 

These are also nice but HIGH dollar

http://www.austenitex.com/Shop_By_Ca...mp-for-Welding

 

Wouldn't this possibly contaminate the aluminum weld though? If not, the only problem I see with it is that that I'm not sure how well that kind of system will work on things like complex curves (like trying to weld two curved pieces together).

The only problem with my idea is doing something that changes direction on two different axis. Mine would only work on one, and then I'm back to the stupid pinching c-clamp.

 

i use masking tape

 

Just hold it in one hand and tack it with the other, This is very simple. If your not quite good enough to tack aluminum without filler dab filler to one of the tubes on the edge so there is a ball. then you hold them together and tack over the balled section.

Trying to use clamps is clumsy and inefficient.

 

With plenty of practice this can be achieved. This is exactly how i do it and recommend it also. Sorry, no clamping ideas.

 

Same here, if its awkward/heavy get your mate to help. I never even thought of clamps, way too slow.

I do however like the clamp which looks like 2 vbands inverted, looks good for gas coverage, on Ti lets say.

 

http://www.vansantent.com/welding_ac...ice_clamps.htm

 

How the hell do you get the aluminum to tack without filler? I tried this time and time again, and the only thing I ever achieved was getting both sides to separate.

K24, I like those, but they come in a max of 2" OD.

 

+1 clamps seem like they would be more frustrating more then anything else.

 

let the torch establish a good clean arc with very little amperage, once the arc is good hit the pedal and move the torch a little. I would imagine that you are trying to tack it as if it was steel, if you just slam the pedal down real fast your just making more work for yourself and potential ruining the work piece. Also you can start the arc off center of the butt joint and the move in once the arc is established.

 

Usually the speed you apply the heat and back off the pedal. As said, most of the time just put a small dab of filler on 1 side before you tack, then join use this ball to fuse them together.

 

You're right, I have been doing it like steel. Thanks for the tips, I'll definitely be giving it a try to get the technique down. I was under the impression aluminum needed help to tack.

 

My guys had trouble one handed tacking with syncro's and the first gen dynasty welders. With the new 350s though @ 400hz, it's very easy. I've even seen them tack aluminum without a helmet.

 

Yeah, I was going to say, tacking without filler on aluminum is not easy with a transformer machine.

Either way, I still have trouble with this. I don't have trouble getting the metal to fuse, but I find tacks without filler tend to crack on cooling, so by the time you make a second tack, the first one has broken.

I also use the "filler dab on one piece first" trick. Clamps are just too frustrating for me, and it's even more difficult when you are trying to clamp two bends together at different index ...

 

I use 3M duct tape... Super sticky, and can take some heat before the adhesive gets left behind. A small piece gets the job done, and I just peel it off right after adding a bead.

 

Same thing I do, or I use my vice on my bench. If your having a hard time not using filler, burn a little bit of filler on and then pool it on with one hand, not that hard, I don't see a reason for clamps, I'm not using a transformer machine either.

 

I use a syncrowave 200, works fine for me. idk

 

Ive done it quite a bit with a Hobart Tigmate and never had any problems, we are probably just using slightly different methods seems you are a very competent welder

 

have you seen his shop thread?! jk markku does get down..... i have an old school syncro 180 and i just use vice grip clamps with just enough tension to hold it to the table and tack. if they are bends at different i clamp one hold the other and establish arc travel slightly to fuse, make sure they're lined up correctly then put a tack next to the fusion, finish tacking, and smile afterward....