Learn An Old Timer's Secrets To Mig Weld Aluminum Without A Spoolgun

Did you ever wonder how they weld aluminum with a Mig Welder? It can be very difficult, if not impossible. Usually, they use an expensive Spool Gun that is an attachment to a Mig Welder. That allows a welder to get smooth aluminum welds. But, who has that kind of money to spend on a Spool Gun? This video shows how to weld aluminum without any add-ons. With a few tricks and secrets, aluminum can actually be welded with a 110 volt Mig Welder.
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What I have in my kit:
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Some of the items used in this video:

Welding Equipment:

Video Equipment used to make this video:

- iPhone 6, no longer available as New

For Informational Purposes Only. Don't attempt to Mig Weld or do any other type of welding without Certified Welding Training. With or Without that Certified knowledge, welding can be hazardous, and by welding you do so at your own risk.

NEVER open up a welding machine as it can still have dangerous voltage built-up in the electronics.

Whenever changing out consumables on a Mig Welder, first TURN OFF the machine and unplug it, also.

DISCLAIMER: This video and description contains affiliate links, which means that if you click on one of the product links, I’ll receive a small commission. This helps support the channel and allows us to continue to make videos like this. Thank you for the support!

[OleNavy]

Electrically speaking, a MIG welder is a Constant Voltage (CV) machine. You set the voltage and wire-speed needed, so the voltage remains at the setting. The wire speed and wire stick-out from the contact tip are used to adjust the amperage. This is because those two factors create resistance. We are talking about Ohm's Law here. With the wire speed properly set and the proper amount of stick-out, you should have a good buzzing weld arc. If the arc is popping and spattering you most likely have too much stick-out meaning the arc is too cold, reduced amperage. If the stick-out is too close the weld might be too hot increasing the chance of the weld sagging or melting thru in the aluminum. The stick-out is used by experienced welders to adjust the heat (amps) of the arc as they are welding and require a little more, or a little less heat. MIG welders learn to do this and make the adjustments unconsciously based on what they see and hear. Aluminum requires more heat than steel does for a given thickness of the metal being welded. Going past 1/4" inch thick aluminum I have found it is sometimes advantageous to pre-heat the metal a little. Now, SAFETY!!! For all the safety warnings you listed and went over, You committed the MOTHER OF ALL SAFETY VIOLATIONS!!! NEVER EVER MOVE A HIGH-PRESSURE GAS BOTTLE UNTIL THE SAFETY CAP HAS BEEN PUT ON THE BOTTLE. Even an empty bottle can be a danger to life and limb. As a side-note. A SMAW (STICK) and GTAW (TIG) welding machines are Constant Current (CC). You set the amperage and by adjusting the length of the arc, you vary the heat (Voltage) of the arc. The arc spans an air gap between the electrode and the workpiece. That is the resistance used by Ohm's Law. A close arc reduces the voltage, a longer arc increases the voltage. Hope this all helps with your future welding. I couldn't help but respond as I was a welding instructor before retirement.

[maaaak]

As a thirty year welder with miles of aluminum experience let me give my two cents worth. Many great comments from real welders here. Things you did right: using 5356 wire, using .035 tip.
Other things (repeating some things others have noticed):
Wrong ark length setting and you don't need to set the wire feed to the highest setting, that just causes a hotter, higher amperage weld. MIG machines are set by ark length not amperage. The machine gives whatever amperage is needed to burn the wire to maintain the ark length so faster wire feed means more amperage and hotter weld. If the wire moves faster than the machine's amperage can burn the wire to maintain ark length the wire will just pop, sputter and throw off lots of dingle berries or throw a bird's nest in the drive. Slow the wire to lower amperage and the ark length should be set to where the wire burns smoothly (not popping like welding steel with CO2) into a cone shape where the end of the wire burns about 1/8 to 1/4 inch from the parent metal.
Don't wear rings while welding.
It's bird's nest not bird cage.
Don't use WD40 on something you plan on
welding.
Don't start and stop your welds every 1/4 inch, that's just a series of tacks not a real weld and it cause porosity like crazy. Use a piece of clean steel to back up the weld on thin aluminum, don't worry it won't stick.Who uses a file when an angle grinder is available?
The aluminum must be completely clean (sanded clean) half an inch from the weld or the junk on the surface will be pulled into the weld causing lots of porosity.
Do not allow your wire to touch the parent metal when you pull the trigger. Bend or cut it back. If they are touching it's possible for the wire to weld itself to the copper tip if it's not moving when the ark starts, that will start a bird's nest real fast.
Keep the cable as straight as possible, no S curves unless absolutely necessary.

[t.s.racing]

1-Clean part with stainless brush.
2- Then clean with acetone.
3- Replace the gun liner with a teflon one.
4- Pre heat the workpiece.
5- Purge residual gas from welder.
6- Tack each end, then weld continuous.
7- Slow down wire speed.
8- Less wire stick out before initiating arc.

[wolmntn]

I love reading the comments from the welders. I have been tig and mig welding for 40 years. Everyone has their way of welding and aluminum mig takes skill and knowledge. I never used a spool gun for aluminum mig. The bigger tip is key and a clean weld. No need to stitch the weld though run a straight bead and you will have a good weld.

[josephcoffman]

Thank you for taking your time to make this video. I would like to add to Mike Klass's comments. Best tips in the video: 5356, .035 tip for .030 wire, and 100% Argon gas. As for the rest, no need to steamroll a dead horse.

[quadsman]

Appreciate your tip on the mig technique !
I am paralyzed from my shoulders down, and no longer able to weld,
however have a part-time fabricator that I will be sharing your video with.
Once again,
Thank you sir !

[JohnDoe-kpsw]

After viewing many comments, even if your teaching is less than perfect, you got my attention to research this welding aluminum with mig. So for that I thank you

[deltonkillen]

Many good comments here. Great advice from Mike Klass. The #1 rule with aluminum is it's GOT to be clean. I worked in my Dad's sheet metal/fab shop for 46 years. He taught me how to weld all types. I never got as good as he was. But great video.

[andymather]

Exactly what I was looking for. Enjoyed the video. By no stretch of anyone's imagination am I a welder but they did sell me the tools and now I have enough information to try it. Thanks!

[schlusky]

as a welding noob, I would like to thank you for this video. between the video and the comments I have learned a few things that are useful to someone just getting started learning how to weld.

[seniamcclurg]

Wow you have one of the best methods Iv'e seen, thanks for passing the old-timer stuff on!

[B.G.]

Appreciate your attention to the many details to consider. Very nice and high quality video. I have always wanted to try welding aluminum and you have given me enough info to pursue. Thanks

[TheMadHermit]

Great informative video. Production quality was on point! Audio was fantastic and was blown away that you recorded everything with your phone. Well done Sir. Hat tip to you.

[oregonone]

I learned aluminum welding having to weld propellers with stick in 1970. (no leasons) 1972 we bought our first wire feeder for steel. Aluminum wire welders were a nice treat in 1985. Thanks for your nice work from a boat builder and job shop owner.

[Edgardocelectric]

Regardless of the negative comments I did get a few good tips from your video, at least I have a very starting point for my project so unlike so many comments I read I thank you

[oldmountainmarineandmetals]

I have the SP-100 and I love it! I don't have any problem welding aluminum either

[sebroberts]

I heard that you can weld alloy with a mig. This is a good starting block to learn and grow from. Thanks!

[hoodyoverkill]

A grinder would come in handy bud. Thank you for your video

[ronslaughterandalice]

Great video ! You got her done and it looks like your son can get his drywall finished now. I have a very old welder ( 220 single phase ) and I'm going to get a bottle of argon and give it a try. Personally I'm not a welder but I had a weld shop in Dachau Germany while in the Army and welded in most every machine shop I ever worked in. I just play with the machine and setting on a piece of scrap until it taste right then i finish cooking it. I could read all those books on it but I'm lazy.

[johnknowing-zrde]

Best vid on this so far Thanks I've stick weld my heavy equipment, Mig weld my tools. Going to now weld alu