Aluminum Welding Tips for Tig

Scroll down for links to more pages on Tig Welding Aluminum

This video shows revision 1 of the bike seat mod but also lots of clips with tips of aluminum welding tips using Tig.

A good friend of mine goes to a spin bike class and now wants her Trek bike to feel like the spin bike she uses at the gym.

That meant modifying her seat post and adding some gussets...but I agreed to give it a go and that video posted a couple of weeks ago. 

This is Rev 1 and I hope its done because I have lots of bigger projects on the horizon. ( like a big steel tubing lifting fixture that is a good job for pulse spray mig)

Why doesnt she just get a new bike?


Shes is a small girl and just cant get the bike to feel right which most likely means she has the wrong size bike frame. She likes the way the spin bike at the gym fits her and that is what she wants out of her Trek bike. 

She is happy with the way the bike feels now.

A lot of folks who knew something about bikes emailed and warned me that this was a bad idea and that she just needed a new bike.. but she has had the bike for 20 years, she is not likely to sell it and get a new one.

Something about the position of the knee related to the pedals...etc.

But the spin bike she uses has about 10 inches of adjustment on seat travel and she likes the way it feels.

I figured... what is the worst that can happen? It doesnt work and we buy a new seat post and start back at zero?  no problem.

 Anyway, revision 1 didn't make for much of a video so to make it more interesting, I added lots of other clips from previous videos showing some slow pulse at 0.7pps, and some lap joints, and butt joint tips.

Here are several other pages with tips for aluminum welding with TIG.

Ac balance setting for Tig

Description:  this videos explains AC balance settings

AC frequency applications

Description: a few applications for AC frequency adjustments on Aluminum

Aluminum welding vertical 3g butt joint

Description: This video shows tips for tig welding aluminum vertical uphill 3g position using .125"  (3mm) 6061 aluminum. 3/32" (2.4mm) 2% lanth electrode and 3/32" (2.4mm) 4043 filler rod

Welding aluminum horizontal 2g butt joint

Description: This video shows tips for tig welding an aluminum butt joint in horizontal 2g position using .125"  (3mm) 6061 aluminum. 3/32" (2.4mm) 2% lanth electrode and 3/32" (2.4mm) 4043 filler rod

Aluminum Tig Welding Drill

Description: This video shows tips for getting better at tig welding by tig welding aluminum beads on a plate...lots of them.

Right handed, left handed, long arc, short arc, lots of torch angle, and none, this is the time to try stuff pay attention to what works.

This excercise will keep that filler rod hand busy.


Enjoy this page? Please pay it forward. Here's how...

Would you prefer to share this page with others by linking to it?

  1. Click on the HTML link code below.
  2. Copy and paste it, adding a note of your own, into your blog, a Web page, forums, a blog comment, your Facebook account, or anywhere that someone would find this page valuable.