Paul:

Jerry Hey tells me it's nearly impossible to weld 1/2" aluminum.
So I redesigned this left side engine mount, welding the 3/16
thick pieces out of steel, and bolting in the 1/2" thick aluminum
piece with 3.5" long 1/4 inch bolts.  Do you see any problem
with this?  The aluminum part needs to be 1/2" thick or greater
for the rubber isolation mount.

Perry

Not impossible. Merely difficult. First of all you need a REALLY
BIG tig welder. Actually it is easier than Jerry thinks if you
warm it up to 500 F before you start welding. I have seen
plenty of 1/2 inch stuff done with a small 175 amp tig welder
by using this method. You will need a temp controlled oven
handy.

Looks great Perry. No problem with four 1/4 inch bolts in
single shear. Each single shear bolt location will take in
theory 7,000 pounds at 150,000 psi.

Paul Lamar

Mark Steitle wrote:

There is another way to weld thick aluminum by going to DC-Reverse
Polarity.  It takes some practice and doesn't produce quite as pretty of a
bead, but it does work.  The DC-Reverse polarity directs more of the heat
into the base material. -- Mark

 
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