How does one go about "welding" aluminum? I know you can't weld it in the traditional sense, but how would I go about attaching two pieces of aluminum pipe together. One side doesn't have enough length to use a rubber boot.

Here is what I have:


Here is what I want to do:


Thanks

 

The best thing you can do is take it to a local machine shop. For $25, they'll weld them together - and do a professional job too!

 

Its a tough art to do yourself. You will need a TIG (Preferred) or a MIG (What I can afford), Argon Shielding gas, A clean SS Brush, Acetone. I am just learning and its frustrating as all hell!!

Take it to a good weld shop and fork over the $$$$

 

So off to a machine shop I go. That definantly sounds cheaper than finding the equipment to do it myself.

Thanks

 

what kind of intercooler are you trying to mount ?

 

The project is still a long way from complete, but I have a Starion Front mount. That could change though as funds become more available.

 

I wouldn't put a connecter on the other side either... should probbaly be longer.. unless you are gona weld something else onto the other end too.

 

well if its not subject to a lot of heat you can possibly use jb weld... but i would just pay $$$ and get it done by a pro

 

Just do as the other have suggested, take it to a welder, I am learning right now how to weld aluminum and its hard. But luckily my welder is my dad

 

Is that little corner a pre-bent pipe you can pick up at jegs and rice boy shops (seems a lot of them have those lol) and cut to length?

 

well.... for aluminum its ... extremely hard to weld it ... welding forehand will give you a better look to the weld, and welding backhand looks like crap ... and has more penetration.. this is with a push system i believe it is... this stuff was for the MIG process .... i hear tig is alot harder, but everyone has their own preferences....... and using straight argon seems to give more undercut on the sides of the weld .. so use like 1-3 % oxygen and the rest argon i believe it was... it helps to wet out the edges....... just make sure to test your stuff out if ur gonna try it.......
as for equiptment ... i cant think of much more then what others have said, but wear protective clothing and have a shade10/11 lens while welding.
good luck with it all

 

Actually, it is a piece cut from some Saab 9000 Turbo intercooler piping. I have other sections, but I wan't that one for a 90degree upward bend.