Need help in a big way

[NewbieClueless]

I am new to this and have no one to help. I have to weld together two pieces of aluminum that are clamped together in a stand up metal vice right now. I cannot get my return cable on the small pieces and wanted to know if it was okay to attach the return cable to the metal vice??? Also, when welding aluminum can you attach the return cable to aluminum??

After this is completed, the newly welded pieces of aluminum then have to be welded to an aluminum frame. So same question again, can I run the return cable to aluminum? And if not, where could the cable be attached? I am putting this aluminum piece onto an aluminum car frame underneath.

Desperately need help so I don't kill myself here

 

[Screwdriver]

Yes. Aluminium is a very good conductor.

You might want to clamp to it where it won't show, any slight mis/disconnection will leave a scar if the current arcs.

<edit> you may want to clean the vice down to good bare metal where it touches, just to make sure you have a good connection.

 

[wyn]

Are you using that arc welder?
Is that an aluminium rod?

I don't think it's going to work very well.

 

[frank horton]

sad BUT better pictures of the vice pls.....

 

[Ace Paul]

Never welded Aluminium myself. A friend of someone else who has welded everything you can mention in steel says Aluminium is harder than it looks.

I might get told off by moderating team for this:-

Can you pop rivet it instead.

If you never welded before might best not if a one off.

 

[redlig]

Perhaps a quick glance through the Welding Techniques pages on here might be worth while.

 

[bourbon]

Wasn't there a thread on here that said those gun type welders weren't much good?

 

[BrokenBiker]

Wasn't there a thread on here that said those gun type welders weren't much good?

I think the general feeling was they worked, but the short leads hindered them and no one was brave enough to crank them to max capacity

 

[BrokenBiker]

I dont want to burst anyone's bubble here and appreciate that everyone starts somewhere, but you really have chosen the hardest way to try and do this job...

An import 'gimmick' stick welder, Which in my opinion is simply the hardest process for welding aluminium plus it appears you will be welding uphill, which is again one of the hardest positions to weld in and I'm not even sure if aluminium stick welding rods are all positional either. I have been stick welding for 15 years on and off and I've never been able to make a decent aluminium stick weld...its a large factor towards why I bought a tig welder.

Finally though, as much as I admire anyone who can openly admit they dont know what they are doing, I can never advise that your first attempts at welding are on a frame that will mount to a road going vehicle.

That said, I do have words of advice as well...yes you can clamp the ground lead to the vice, but make sure the vice has a good clean connection to the aluminium. You can also clamp it to the aluminium with no issues. You need to clean the aluminium until you think it's clean, then go some more...you are going to struggle with aluminium rods so a lot of practice will be needed first which isn't ideal as aluminium isn't cheap and practicing in steel won't really help as it's completely different to aluminium with regards to feel, travel speed, heat etc...

Personally, this is one of those jobs where you find a welder and throw them some beer tokens and ask could they weld it up because you are struggling with it. Alternatively we have plenty of members on your side of the water that may be willing to assist with a TIG or even a MIG

 

[fizzy]

I am new to this and have no one to help. I have to weld together two pieces of aluminum that are clamped together in a stand up metal vice right now. I cannot get my return cable on the small pieces and wanted to know if it was okay to attach the return cable to the metal vice??? Also, when welding aluminum can you attach the return cable to aluminum??

After this is completed, the newly welded pieces of aluminum then have to be welded to an aluminum frame. So same question again, can I run the return cable to aluminum? And if not, where could the cable be attached? I am putting this aluminum piece onto an aluminum car frame underneath.

Desperately need help so I don't kill myself here

Welding aluminium isn't easy. I have an industrial tig welder and plenty of stick and mig experience but I still struggle. You are better off cheating. Epoxy will work well if it is a big surface area. Another option is rivets. Or both!

 

[BrokenBiker]

Welding aluminium isn't easy. I have an industrial tig welder and plenty of stick and mig experience but I still struggle. You are better off cheating. Epoxy will work well if it is a big surface area. Another option is rivets. Or both!

Nut and bolt seems the quickest, cheapest, easiest and safest option

 

[Ace Paul]

Welding aluminium isn't easy. I have an industrial tig welder and plenty of stick and mig experience but I still struggle.

For reference what is difficult? Like trying to butter bread with melted butter verses frozen butter? Or other examples?

 

[BrokenBiker]

Seems we may have put the OP off...no response since first posting

 

[Ace Paul]

Seems we may have put the OP off...no response since first posting

#OPW One Post Wonder. Came across somewhere, was full of them

 

[wyn]

Seems we may have put the OP off...no response since first posting

Maybe trolling with that welder and arc rod.

 

[dieselsamurai]

Without the necessary skill/experience I think finding a different way to attach to the frame would better ie bolting or riveting. Welding isnt always the only option

 

[BrokenBiker]

Maybe trolling with that welder and arc rod.

I'm also confused as to why the part needs to be welded in the vice...its not exactly large