AlumiWeld

[joez3]

I need to replace some doors on my small shed, they are currently a 2x4 frame covered with some 1/4 ply wood. They weight a lot and are no longer square. I was thinking of making a new frame out of some square aluminum tubing and covering that with some plywood.
I don't have a welder so I was thinking of using AlumiWeld to weld the tubing together. Has anyone used this? Will it be strong enough to make a door out of?
Thanks

 

[Fueler]

If you have a proper torch and know how to braze it "should" work.
Practice on some scrap first.
If you can't meet those two criteria spend your time making proper fits and take it to a pro welder.

 

[garfunkle24]

Works well if done right. Key is removing the oxide layer, either with a clean stainless brush or by using aluminum brazing flux. Aluminum being a good heat sink, it can be difficult to get enough heat into bigger parts with just a propane torch. Here in Canada we can't get MAPP any more either, just the MAP Pro stuff which only burns like 100*f hotter than propane.

 

[SGKent]

I'll bet you can find someone with a tig welder who will do that frame for you relatively inexpensive. By the time you buy the alumiweld, practice and work on it, you could have it done right cost and time wise, and help support a local business.

 

[jubilee]

Have you considered riveting? HF sells a 1/4” hand (and 3/16”) riveters cheap and they’re alright. I’ve had a 1/4” HF air over hydraulic rivet pot for over 20 years. Probably set a couple thousand rivets with it. Also have the hand tools.
I’ve been welding aluminum for over 45 years. Have the equipment and can do tig, spool, and stick, but never could master a torch on aluminum.
I would suggest a hardware store L bracket riveted on inside corners. Paint both the aluminum and bracket first to stop electrolysis. Then, aluminum flat over joint on side opposite plywood.

 

[PugetDude]

I repaired a cracked aluminum screen door on my Airstream trailer with the Hobart low-temperature aluminum welding rods. Key was to brush the joint with a clean stainless brush before and during the heating process, right up to the point the alloy flows. Maybe I got lucky, but I fixed a 3" long tear where the hinge mounted, it filled the crack nicely and the color blended perfectly.. I did stop drill the crack before I did the repair; it never broke again.
Try it, you can get the Hobart rods at HD, cheaper than the stuff they sell at the county fair. Get really good at it and you can weld a decorative gusset plate over your **** joints.
Good Luck!