I'm wanting to make a sheet metal intake plenum, think it will be a fun project to practice on. I'm looking at using .1" (2.5mm) T6 sheet, but I don't know if I should use 3/32 rod or 1/8

Literally all the info I need I found on Miller's website except for this. After a good search elsewhere I remembered my Honda brethren could probably help, thanks for any advice

 

1/16" or 3/32" filler. Depends on joint. Also, it is on their website...

Miller - TIG Welding Calculator

 

Thanks! I actually saw the tig calculator link on a page and clicked it, but it took me to a different page...weird

 

I used 0.100" 6061 aluminum for the meth tank I built for my car and 3/32" 4043 rod worked beautifully. 1/16" probably would have also worked fine, but you would have to cram it in faster. I think ⅛" would probably be way to big, although I haven't tried it.

 

Aluthman, I think I actually saw that going back over 98vtec's thread after I posted this, those were some great welds. I ended up buying 4943 in 3/32", apparently 4943 welds even better than 4043

 

I have found that aluminum is a lot more forgiving for the filler rod size than steel is regarding puddle feel.

That said, I would go with 3/32. The amount of heat you're going to want to put into a .1" wall plate will probably give you issues with melting the filler rod in front of the puddle with 1/16"

 

I honestly have used 3/32 for everything from 1/16 alum to 1" alum.

 

i typically use 3/32 for most everything.