TFS: How to Bridge Gaps and Holes on Thin Aluminum

By very popular request, we created a video dedicated to bridging gaps on thin aluminum based on the episode all about filling gaps on thin metal (steel). While this gap may be a bit extreme as shown, the techniques demonstrated to control it still hold true.

Special thanks to Blue Demon Welding for sending out a ton of filler rod used in this episode. Check out the link below to pick up some cool Blue Demon products we regularly use!
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Bridge Gaps in Steel Episode:

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[joelbrown]

As a sheet metal worker I've come across this situation countless times. Love your instructions and disgust! The reality of working in a ceiling with 12" of space to crawl through to get to the weld area... you are a breathe of real world application. Thks

[weldingjunkie]

“ if your fit up game is this bad then not knowing how to bridge a gap isn’t your problem” LOL I’m still rolling. Great video brother.

[Wenvalley]

More close ups of the finished weld would be great. I know you got a close look, it would be great to show that to the viewers too. Nice job, I enjoy your teaching style. Very nice.

[split]

Great tips.  Until someone tries to tig aluminum that's not cooperating, they will never appreciate the delicate touch your example took to pull off.  Thanks.

[justtinkering]

This was a great video. Real world repairs are not always perfect. Thank you.

[vintagespeed]

i was glad to see you mention that what's important is matching YOUR SPEED to your settings on the machine. either hot & fast or cold & slow. most ppl say there's only one setting & one speed that works, which isn't true. it's all relative to how fast or slow YOU are moving. good stuff! that thing would probably buff out if you got it low enough!

[JeremyWilson]

Want to thank you for giving me hope where before I was hopeless. Yesterday and today were my first TIG aluminum attempts, and the gap bridging was really hard. It turns out that the techniques I stumbled on were pretty much what you showed, with similar results. So, onwards I go.

[robwashburn]

I weld odd shaped extrusion all day with loads of gaps from non welder fit up. I love the videos! You have helped many, including myself. Thank you

[JohnDoe-qh]

I've been welding for 35 years! And your right ! Gaps are hard to weld !

[sc]

Any way you could put a PIP with the pedal, would be sweet to see what your doing with foot/amps

[johnbrevard]

You made all the sense in the world about amps and how they effect pedal, so setting the machine to 20 amps you have full pedal to adjust from cranked to 200, your going to have to have a smart steady foot to maintain say 13 amps....Awesome video man!!!

[rambos]

I know this channel is more of a auto fab channel, but this is pertinent to a lot of metal fab shop and manufacturing applications. I’ve received aluminum parts with 3/16”-1/4” gaps because the press machine was goofy, or the laser cutter fucked up. You just have to know how to do these gaps. Great content as always.

[poogy]

Aluminum plus gaps=big challenge. You gave me some ideas to float around and try. Thanx!!!

[tactownturbotime]

Dude thank you so much for sharing all this tech info. I just bought my first ac/dc machine and am learning so much more from you than from my dad that works at ingersol rand. A welding company!

[joewhitney]

This was very helpful. I don't have a lot of skills or knowledge of tig welding aluminum but want to learn. I recently had a repair of a driveline for my cousin and interestingly enough, the tube pretty close to what you were showing. I struggled a lot getting it fixed for him but would have benefited a lot had I seen this prior to the work.
Thanks for sharing.

[danl.]

Ugly schmugly my shiny behind. That was a VERY informative and helpful video. Tone of useful information and I learnt a lot. That was a super good video Justin.

[oby-]

When I weld tears in aluminum irrigation pipe much like your example, I always use a patch or band-aid as I call it. Irrigation pipe is not structural but has to contain pressure. I would not be able to bridge a gap as wide as that. Takes real patience for that.

[NellsMechanicalManCave]

Been welding for 40 years but only just taken up tig.
Thanks for the in site, very similar to how I've filled with stick on steel. Won't be trying what you just done any time soon thought, I don't have anywhere near your level of control yet. Keep the videos coming please, they are a great help !

[Fullchiselchainsawartistry]

I live in the real world of working for the government, sometime our budget doesn't allow us to buy material and well we have to use what we have. This was great. For us it's about functionality. I try to make it look good, that's pride, but in a case we're I could learn this it could really be helpful and get us out of a pinch! Good stuff brother. God bless and thank you

[pairadice]

awesome video and great explanation! the only times i have ever experienced a gap THIS large is usually when im tasked to fix a part that has chipped out a nasty gap and it has to be welded to fit something specifically, thus i had to close it. never pretty but sometimes it happens!