Honch
Well-known member
I'm starting this thread versus posting to the "Garage Gallery" I have more going on in the garage than to the garage.
Over the 11 years I have owned my Corvette I have changed or modified multiple things on it. It has been a very dependable vehicle with only a few things actually breaking over the years. One of the very first items that broke right after it came off warranty was the lower radiator support. This is a common failure item that in some cases fails due to abuse but is mostly just poorly constructed. Its made entirely of aluminum and generally fails because the welds have no penetration and literally break apart.
That's what happened with mine and at the time I had no way to repair it so I ended up spending over 250 dollars on a replacement unit.

Now eight years later, the replacement unit broke in at least three different areas, one of which is circled above. This is one of the reasons I wanted to be able to weld aluminum, unfortunately it isn't how I wanted to learn to weld aluminum. To date I have maybe two hours total time tig welding and a third of that tig welding aluminum.
Here is the same bracket on the other side.

These are a few of the welds I did to reinforce the structure of the radiator support.


I still have some work to do on keeping the weld area clean, these aren't as contaminated as they look, the black flakes are from the wire brush flaking the paint.
Not the prettiest welds but like a professional welder told me, "Welds are like your children, even if their ugly you still love them".
Over the 11 years I have owned my Corvette I have changed or modified multiple things on it. It has been a very dependable vehicle with only a few things actually breaking over the years. One of the very first items that broke right after it came off warranty was the lower radiator support. This is a common failure item that in some cases fails due to abuse but is mostly just poorly constructed. Its made entirely of aluminum and generally fails because the welds have no penetration and literally break apart.
That's what happened with mine and at the time I had no way to repair it so I ended up spending over 250 dollars on a replacement unit.

Now eight years later, the replacement unit broke in at least three different areas, one of which is circled above. This is one of the reasons I wanted to be able to weld aluminum, unfortunately it isn't how I wanted to learn to weld aluminum. To date I have maybe two hours total time tig welding and a third of that tig welding aluminum.
Here is the same bracket on the other side.

These are a few of the welds I did to reinforce the structure of the radiator support.


I still have some work to do on keeping the weld area clean, these aren't as contaminated as they look, the black flakes are from the wire brush flaking the paint.
Not the prettiest welds but like a professional welder told me, "Welds are like your children, even if their ugly you still love them".














































































