I started with Tracy's plate and trimmed the plate across the bottom
parallel with the oil pan rail. Then used the PSRU mounting bolt hole at
about the 4:30 position with a longer than supplied bolt to pick up one of
the mounting ears for the starter. I then welded a "finger" onto the plate
to pick up the other starter mount hole. After welding I dressed off the
weld bead with a belt sander. This puts the starter at about 3:30.
Relatively easy for the shade tree types without access to machine tools.
Mike Wills

Nice work Mike. You would need to farm out the tig welding of course.
My 175 amp tig cannot weld 1/2 inch plate.
Paul Lamar

Blake Mantel wrote:

Oh yes you can Paul!!!

I had to figure out how to do this on a 4" OD rod of 6061-T6 which needed a 5" adapter
plate to mount an antenna at a local airport. I own a Miller EconoTig (I want a
SincroWave 180 :) which will get up to 160 amps when I push it.

Get some standard building fiberglass insulation and wrap it around ALL the other
areas not being welded. Start with DCEN and heat it until the area gets to weld temp.
Switch to AC and go for it!

Be careful because you have a large thermal mass and watch out because you will be
heating for a while and then it will suddenly slump.  Just wrap your plate and it
should work .

Good Luck,
Blake

Good tips. Thanks.

I have noticed that when welding even .125 tubing. It takes a while to heat
the part overall and then it starts to melt faster. I have to back off on the 
foot pedal immediately after that happens. I guess if you heat it to 500 or so 
degrees in an oven it starts melting right away so you don't have to change the foot 
pedal so much at first. I never tried 1/2 inch but I blew the circuit breaker
trying to weld on 1/4 inch. I did not heat it in an oven first.

Things like this are what makes welding aluminum so difficult.
Every different kind of joint has different heat transfer characteristics.
Aluminum has high heat conductivity so something as obscure as a draft in the welding
area can make a big difference. I find I have to mock up a joint to practice on 
before I weld the final part.

Steel on the other hand has low heat conductivity compared to aluminum
so it is much easier to weld.

Paul Lamar
 
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