A whole lotta fail in this one

[Jlg]

So next problem...

Im trying to replace the hose from the regulator to the machine. What fittings/clamps should I be using? The original hose had a compression clamp thingy to the machine. Can this be replaced for something better like a quick disconnect?

This is the hose connection on the back of the machine.
View attachment 130760


I'm also trying to replace the torch with one I got from Richard. It has a different fitting for the gas line. Should I keep the quick disconnect or change to something else? And is a jubilee clip good enough to secure the hose?

This is the original quick disconnect fitting.
View attachment 130759

The one on the new torch. Sorry crap pic but its threaded.
View attachment 130755

And if you use a dremol and carfuly cut the crimped bit on the new torch you can save the hose tail

 

[HughF]

Single ear clips are what you need mate... I'd use a short length of hose crimped onto the back of the machine, then use a rectus 21 male crimped into that. That way you have a whip hanging out the machine without having to take it apart.

For the torch, just cut the nut/tail fitting off the gas line and fit the rectus 21 into the line in it's place.

As for the aluminium, more practice needed I'm in town for a week in early March, I might be able to pop down one evening depending on tube stations etc.

 

[hooblah]

Ok thanks guys. I'll give it a bash when I get a chance.

Richard i'll see how it goes, but I may just give it to you if I can't find the time to crack on with this.

Nice one Hugh! Just give me a call when you're around

 

[Richard.]

Ok thanks guys. I'll give it a bash when I get a chance.

Richard i'll see how it goes, but I may just give it to you if I can't find the time to crack on with this.

Nice one Hugh! Just give me a call when you're around

Send me all the parts if you get to that stage so I can copy them. I’d rather cut and fold them myself from scratch. Pm me if you want a price.

 

[mcostello]

I struggle with Aluminum most of the time. Now and then it looks like I know what I am doing, just not always. I had a repeat job that is 1/2" thick(MM?) always have trouble getting started. 190 amps works best as 250 amps blows the corners off at My skill level. I use a dedicated stainless brush and clean with Acetone or (cheaper) Alcohol. This time I used a commercial Aluminum cleaner from the welding supply and used preheat to 350°. Bingo everything worked. Cleanliness evidently cannot be overstated, preheat worked wonders. Now to remember the next time.

 

[hooblah]

Send me all the parts if you get to that stage so I can copy them. I’d rather cut and fold them myself from scratch. Pm me if you want a price.

I'll go one better... I made the tanks using cad, printed out, stuck to ali sheet, cut out and folded. I'll send you the file if we get to that stage

 

[Richard.]

I'll go one better... I made the tanks using cad, printed out, stuck to ali sheet, cut out and folded. I'll send you the file if we get to that stage

I’d still want the parts as well.

 

[hooblah]

So we're back to this and I've been practicing today on 2mm ali at 80 amps with pedal control. I've only touched down once doing this so not too bad.

I got some scraps and laid a few beads. This went pretty good. The long line was the 3rd attempt, which got a bit hot in the middle so I backed off and managed to save it. Pentration was good.



I tried an outside butt joint but it burned like noone's business

So then I tried laying the piece at an angle and welding an inside butt joint. The first attempt went ok, a bit wobbly but not too bad. Penetration was lacking though. That's the bit on the left.



Then I tried a couple more which just went to ****. The upper piece just kept burning back, no matter how much filler I added. It was also dull and with little penetration. The last weld came out ok (on the right), but still dull an hardly any penetration.



So any advice?
The fitup is ok, it's not tight tight, but close enough.

 

[Richard.]

it's not tight tight

This.
If your doing an outside corner on 2mm aluminium you want the fit up tight tight.
Give it a gap and you’ll be taking the edges away before you can fill them.

 

[hooblah]

But what about the rest? It doesn't seem to be going nearly as smoothly as it went when I was round yours...

 

[Richard.]

Because at mine you had me setting you up with nice tight joints, nice conditions and slapping your wrist. I told you that attempting a fabrication like this with thin gages on outside corners and no backing isn’t something your going to learn in 4 hours. You need to keep practicing. You haven’t done much practice since your session at mine so your going to be starting over. It’s something you need to be doing all the time to keep your hand in.

 

[hooblah]

Makes sense. I'll keep practicing and update soon

@Richard. Can you explain why in the 3rd pic it all went wrong? The pieces had minimal gap, they weren't at right angles so the outside edge was lifted higher. Should I have been using higher amps? It did take a little while to start puddling, and I tried to add filler to the pool and encourage it to take on the other piece, but as soon as I walked the arc across it just burnt through, no matter how much filler was added.

 

[Richard.]

It did take a little while to start puddling, and I tried to add filler to the pool and encourage it to take on the other piece, but as soon as I walked the arc across

Sounds like this was the issue. When your tacking you should not be waiting for a pool it should be instant. It doesn’t matter whether that pool is on one or both sides but it must be there. Then you add filler NOT before. Once it’s got a dab of filler you now have time to encourage it to take to both sides. This whole process should be very quick. Never try and add filler before the pool is fully developed and don’t spend too long trying to develop it. Either case will end in tears.

 

[Richard.]

If my joint is tight I would be tacking up with a torch switch on fixed currrent or flooring the pedal. 2mm tight fit joint I would be doing that at 100 amps maybe more.

 

[hooblah]

Thanks. I'll give it a go tomorrow.

 

[hooblah]

What does this mean when it just keeps melting but the filler won't stick?

 

[Jlg]

It looks very contaminated

 

[Richard.]

Looks like filling before pool development to me.
Can’t be sure without it happening in front of me.

 

[hooblah]

The pool isn't really developing. It just melts away and the filler won't stick. Looks quite crystallised and skinned over as it melts. Not sure what's going on.

 

[Richard.]

The pool isn't really developing. It just melts away and the filler won't stick. Looks quite crystallised and skinned over as it melts. Not sure what's going on.

Start from the beginning
Go through all your settings
Amps, tungsten type/size, gas flow, balance, frequency, filler type/size basically all details
Let’s have a look at the set up and go from there.