How to Cheaply Weld Aluminum

Welding aluminum with a new MIG or TIG welder can be prohibitively expensive, especially if you don't plan on using your welder often. As a low-cost solution, you can take a chance on purchasing a used welder; alternatively, you can purchase a hot shot spool gun welder. Hot shot spool gun welders are inexpensive, portable and offer many desirable characteristics, including precise wire control, their ability to weld up to 3/16-inch steel and their ability to weld substantial distances away from the welder.

Things You'll Need

  • Hot shot spool gun welder
  • Aluminum wire spool
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Instructions

    • 1

      Place a spool of aluminum wire onto the welder axle.

    • 2

      Feed the wire through the wire assembly, over the wire roller and into the torch hose. Lock the wire in place by lowering the tensioner.

    • 3

      Depress the trigger on the welder to feed wire through the tip of the gun. Fire the gun and move it in either a straight or wavy motion, depending on the thickness of the aluminum being welded. Thicker aluminum can handle a straight motion, while thinner aluminum will require more of a zigzag motion.

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