Tig Welding Aluminum Pie Cut Tubing
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- เผยแพร่เมื่อ 5 ก.ย. 2024
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Tig welding some aluminum tubing for a car intake duct. thank you to S1Built in Clearwater Fl for supplying me with some pie cut pieces for this video. Also thank you to Roy Crumrine - Crummy Welding LLC
A little bit of a fixturing tip for all of you. I do a lot of custom pie cut exhaust work. I use hose clamps (gear clamps) to build my assembly and hold my pies together. For larger diameters I've drilled holes in my clamps for access to make tack welds. It works great and holds the orientation of my assembly really well.
When I was growing up, young lad, there was the opportunity to take a shop class in school. I skipped that opportunity and 30 years later wish I had not. What you offer us in these videos is what we may have missed, or education not offered in today's schools. Anyone hear of a shop class these days? Not here, not near DC. So, thanks for sharing what you do.
I'm a junior in high school and we have a shop/welding, advanced welding classes hear in Texas. I've been welding all year, although my teacher doesn't teach us how to weld, I've thought myself stick, mig, and tig welding.
Don't kid yourself Jody, this here is the "ONLY" place to be for welding videos on TH-cam! I just enjoy watching a master (or in this case, a couple of masters) at work. Pure welding poetry!
Hi Jody, there might be other welding channel choices out there but they don't even come close to your channel. You are the gold standard when it comes to welding with integrity and precision and detailed information. The video quality is the best, the voice over narration is the best. The subject matter is great. Thank you so much!
+Peter Kerekes thanks very much
I agree 💯%!!👍
We watch your videos in my welding classes over at the college. You're an incredible welder and your videos have helped me immensely!
I go back and watch your videos from time to time. Learn something new each time. Im Getting better tigging all the time. Your torch manipulation just works. Trying to imulate your style. I like it. Thanks Jody
I haven't seen any other videos that come anywhere near close to the quality and knowledge you give Jody and with a good sense of humour :)
Many thanks, learned lot from you the last couple of years.
hey Jody just wanted to give you props bud I'm a father of 3 kids and married I recently landed a aerospace job 2 months ago that required welders to pass a 6g aluminum pipe test on 6061 aluminum 3" pipe .065 this particular video really helped me with my starts and stops on this test.it was not a easy test but I just passed it the other day they cut 4 sections out of pipe and bent those and the end result was flawless thanks for all you do
was it in Ann Arbor? lol I had to take the same test but the older guys with longer resumes beat me out
Nope saline Michigan
You should check it out they're looking for tig welder now liebherr aerospace
@@christrusty6070 Ye they called me recently... I lost her # trying to get back in touch with her... forgot her name
In my opinion you make the best most informative videos on welding that are available. I took welding at a 2 year college and finished but I'm rusty cuz I have not welded much in 6 years. Your videos have helped me remember a lot that I forgot. Thanks for what you do in helping us guys.
Jody I've been welding self taught for the last 14 years I can weld aluminum but after watching your videos I feel that I've learned alot I'm not good with all the technical aspects of welding specially when it comes to aluminum but your videos help alot thank you
This guy is ridiculously good at what he does.
great work im supprised the tape was enough to hold its shape in the 1st place,
yeah I thought that. seems like it would want to twist.
Hi Jody, Thank you for the video's you make it very understandable. I've been welding for 37 years and you are never to old to learn new tip and tricks. Thank you Joey Sams
Another addition when welding angled joints is to weld the outer radius first. This holds the angle better as welded joints always want to tighten to the inside radius.
Great to see in detail how to handle the tack welds, including the technique with torch and the welder settings. Seeing how nicely your welds turn out is a great target for knowing what is possible!
Hey Jody, I know this is an older video of yours, (I'm just going with the flow that TH-cam gives me on autoplay) I've noticed at the end of the last 8 of your videos I've watched that you are always sure to mention that you know how many other channels are out there and how appreciative you are that someone chose to watch your video(s). In addition to how informative your videos are you express general gratitude towards your viewers .That's pretty damn awesome in my opinion. Been subscribed to your channel for close to a year now, never a bad video! Keep up the good work bud. I can't wait to be able to afford a decent little TIG machine and get my feet wet. But for now I just live vicariously through your videos.
This is the kind of channel you learn from. Love your videos and because of you and your very well made videos, my instructors dubbed me a welding prodigy. Thanks to you and your videos. I greatly appreciate and am honoured to have found your channel.
~combination welding student
Thanks Jody. The stab and swirl technique worked really well for me on some 0.032" walled aluminum tube. Very tricky stuff at 3/8" o.d. After a few days of fustration; 25% balance, 17-20 amps, 90 Hz frequency seemed to work nicely. The correct frequency and balance made all the difference.
Your explanations are excellent and you are a natural teacher. I've done lots of mig off and on over the years and plan on doing more in the very near future, but I really want to try tig. Thank you so much for these videos.
thanks for yet another lesson on how to tig weld aluminum. im based in south wales UK. im learning just from your videos.
Yes! Thanks Jody! I tried the tapered tungsten this evening on 0.065" Al intercooler tubing doing butt joints. It's much easier to strike an arc and get a tack than with a balled electrode. I'm using 1/16" 2% Thoriated (need to try lanthanated) and 1/16" filler rod. I put a dab of rod on each side of the joint and then try to heat them both up and add another dab of rod to join them. Then use the heat to spread out the weld so it's not so high.
That's a pretty piece of art and Roy's welding just makes it even prettier. Very nice!
Thanks for the video! You guys make it look easy....I've found that it's anything but! The more I practice, the more impressed I get. Your tips for practice, like padding small plates, have been useful. Ditto for the J F Lincoln Foundation recommendations...been reading the books, browsing the project ideas, and waiting for some practice kits to get here. Thanks for the info, the references, and the stubby bundle!
-- Mike
Thankyou, it's rare to see a video of welding thin alloy pipe. I learnt a lot. I always seem to have trouble "horse shoeing" a hole out between the two pieces. Oh and thanks for quoting some of your sizes etc in metric. Now I and everyone outside of usa know what you're talking about. Cheers
This really was an awesome collaboration guys. Amazing editing and transitions Jody. Just joined the podcast patrion, forever greatful for how you have helped me step it up. Be blessed!
Best instructor on the web
Thanks for the advice on machine settings, angle orientation relative to weld placement and always the heat considerations of beads so close to one another. I am getting back into TIG welding after a 40 year hiatus. Happy New Year and I look forward to many more of your great videos
Enjoy your video’s. Speaking from experience, most people don’t know how much distortion and shrinkage can happen with weldment’s like this.
So happy to see this video! Once my header is done i'll be working on the intake parts pretty much the same way. It's really helpful for me to be able to get an idea at least of what the start settings should be and go from there! And a big shout out to the Tig finger! I use it all the time and love it!
+Ryan G (Turbofox) thanks very much
you are good at explaining and i really appreciate your efforts and thanks for the video and outstanding commentary.
Although Everlast calls it "triangular" that is actually a "sawtooth" waveform. It is generated by an integrator circuit which is composed of capacitors and resistors oriented parallel to each other and the time constant they have affects the slope of the waveform. Great videos and keep doing what you do!!
As usual very well presented, thanks Jody. You are the only go to instructor in my opinion, keep it up.
Yeah great video great description of settings etc. I'm trying to get a handle on my 255 EXT have never TIG welded before. Seeing these settings and your descriptions will help me get in the ballpark, at least on 16th inch material trying to do butt welds. I'm sure I have watched this one before, today however I think I've watched it three times. ⭐⭐⭐⭐⭐
I find a chain vice on a v block works amazing for holding odd shapes. That way you can just rotate it . Awesome video
Thank you for doing this video, I actually requested you do a video about welding aluminum piping for automotive use several months ago. So again thank you for taking your time to do this. I will definitely try the tips & tricks you've talked about in this video.
As always-I'm speechless and adore your attitude! Each job is a work of welding art! And very educative, too!
Great Video! Learned a lot! Thanks for all the metric measurements!!!
Greetings from Germany! ;)
Yes, thanks again for metric measurements!
stonecraft98 n
and from Russia
i have been watching you for 5 yrs now thanks for the time you spend and sharing your knowledge i do also get your cds shirts and tig fingers. Im constantly refering pepole to your site its the best one out there,
Hey Jody,
I'm a newbie, but your videos outdo everyone by far.
Thanks and I'm a believer!
Roy did a nice job , that type of work was my life for a number of years , I was a model maker for Delphi thermal systems , HVAC automotive proto type TIG welding aluminum heat exchangers , experimental radiators , heater cores , condensers , evaporators , jigs & fixtures and all types of fittings and component parts , it takes allot of practice and technique to weld thin aluminum to thick all shapes and sizes with out bubbling the inside ,if you had small thin wall parts to be welded such as tubing that cant have restrictions inside you had to be very carefull on the peddle and amperage setting ,4043 filler was my go to rod . stainless steel and inconell types of steels thats another story , gas lens as opposed to a standard nozzle , my preference was a number 5 cup with a 1/16 dia pure tungsten but a gas lens was nice for a deep corners , you can stick that tungsten out of the cup 3/4 of an inch if you had to and still have a good amount of shielding gas , also a #20 water cooled torch was the way to go , also AC balance is a great machine feature for small intricate welding , thanks for posting .
I always have problems tacking aluminium. Next time I will follow your tips. Thanks guys, great video!
+Jack White My technique is to melt other side first, give it a dab of filler, then melt other side so it melts into that filler dab. Last step is to melt it into uniform tack.
been a subscriber for a long time. Been waiting for a vid like this as I've tried this before and ended up making a mess. I'm just a hobby welder who likes to work on autos and would like to build turbo piping systems. It definately is one of my weak points on the TIG. It really helps when I watch your vids. Thanks Jody!
Hello Jodie, always enjoy your videos and even after 30+ years of fab work, still pick up something every time I watch one.
On this one though, I will have to say...... that's probably the most ridiculous and over-worked method i've ever seen for building a multi bend pipe.
Mandrel bends are easily found and the amount of welding would have been reduced by about 75%, not to mention a way stronger and attractive finished product.
Just my 2 cents, to each his own....... thanks again for sharing.
+oz31140 I would agree that mandrel bends would have saved time and quite a bit of welding. But the choice to go with pie cuts rather than mandrel bends had already made by Roy's customer.
First time I've heard cut tube called pie cut. Always been Lobster back to me. Always enjoy your vids Jody. Carry On.
Good vid, thanks. Got to get my hands on a Tig and start teaching myself as they obviously have a lot more uses than my mig welder.
Thanks for posting such informative videos. Hopefully I'll be getting into tig welding soon. Your videos on spray arc aluminium welding helped me a lot.
Hey man. Thanks so much for taking the time and effort to make these videos. There are a lot of welder channels out there but i always learn the most from yours! Keep it up !! Much love and appreciation from the netherlands
Great to see that Jody - bet he needed the TIG finger!
That is one heck of a long job with huge positioning aspects. Lovely work. :)
Great video.
I can't stop watching your videos! I can't wait for my 210 EXT to come in so I can practice.
Another great video, Roy is a welding god!
Hey Jody and Roy. Great video once again. Would like to see more of these thin aluminium tubing and plate welding tricks videos. Keep up the good work. Cant wait the next video...
Jody, another true master, now I know there there are at least two... Great video, shows some great technique your channel is one of the best out there. Keep up the top notch videos I have learned so much for you.
I have found laquer thinner to be much more effective on tape residue and tape left on a long time. Great video as usual. You may force me to install video in my shop! I added TIG to my arsenal last year and don't get much time on the torch as I mostly use the mig machines. I have learned a lot from your channel. Happy New Year to you and yours. Doug
As usual, EXCELLENT video!
Also, I got my tig finger bundle last week, and it changed my life. Love it! Keep up the good work!
Jody - wow, nice work on this project. Looking forward to many great projects this year.
Picked up a M 211 at SEMA. Nice machine. Hope you can demo one in the future.
Thanks, for all your Videos!
The Videos are better Teacher, than such a 'Weldingexpert' how told you only 'trying-trying-trying'.
Try to start with Aluminium this week.
Keep on Dude, best regads from Germany.
Another excellent video. As always, you provide the best welding videos online.
Great video and I agree on so many points. I just did an air intake with pre bent aluminum with only a few pieces. So not nearly as complex. I'm not as versed on aluminum so still feeling my way through it. Of course not cracking is crucial. Watching the up close I was just wondering about penetration. When I did mine I was worried about cracking potential so I was always slower to add filler. But once its going it moves pretty quick and consistent. If say a bit quicker than in the video. Anyways I hope mine holds with no leaks. My welds at least look good and held 40psi. But the one you made here looks sweet
Mate I could watch this stuff for days on end.
spent sometime in your class room this eve Thank you!! Happy New Year Brother!! ..BTW loving the M 211!
Thanks brother. Hope you have a great 2016 too
+weldingtipsandtricks 2016 has been great to me. Got myself a new everlast welder and a bunch of your videos to watch! I'll be ordered a few of your tig fingers soon. Keep up the fantastic videos Jody.
weldingtipsandtricks
Love the automotive application Jody
Interested in seeing the inside of the tube to view what the weld penetration looks like. With intercooler piping (which this is not) the inside needs to be smooth where the weld is to maximize air flow and reduce interference.
Perfect timing. I'm just about to fab up my first intake. Thanks for another amazing video, Jody.
best welding videos in existence
I've just done some of this on down piping. I had hundreds of them to do.
Cool collaboration with s1.
Jody thanks for sharing your experience with all us your tips have helped me out so much at in my business thanks!
Is there any way you could do a short video on how to make the pie cuts themselves? thank you for your videos they're always helpful and helped me get through welding school.
Hi Jody thanks for another great video with great tips and info on the settings you use. 👍
really really nice. 1000 thumbs up for this job and documenting it for us!!!
Still making it look easy. Good work guys.
Good work, Jody and Roy! Here are a few of ideas for future videos that I think would be neat to see:
-Tips for stick welding cast iron with nickel based electrodes
-Tips for Blueprint reading
-Maybe some arc-shots of TIG welding Titanium, cast aluminum & magnesium alloys
-MIG pulse for Aluminum, Stainless, Metal Cored, and Hard Wire
Happy New Years, and greetings from Canada! :-)
+moon47mars +1 to cast aluminum, old/used/dirty cast Al repair on an engine or something would be cool
Tips for welding with limited access would be great. For example, I need to weld a screw to thin galvanized sheet where the access to the screw location is through a 4" high opening that's a couple of feet wide, and the screw will be about 8" back and inside a small enclosure with a 5" wide opening. Why? Well, I have a fireplace enclosure with a blower fan. The blower fan plugs into an outlet that corroded. I have a new outlet, but the grounding lug is solid rust and not usable. I need to make a new one. Sheet metal screw isn't code, soldering isn't wise, so welding seems the only option. Have gas, 110 MIG, TIG and stick available. Tried a test with 1/16" 6013 rod on some thinner galvanized sheet from an old flue pipe...got one good attached screw, one half melted screw, and a couple of 1/2" holes in the flue pipe. Skill is basic beginner but improving...those were my first attempts at stick welding. Any recommendations, or demonstrations, would be great!
-- Mike
Excellent tutorial. Thank you for sharing your knowledge and experience.
why the pie cuts versus alt ways of shaping like bending etc. really like your videos. have learned a lot. thanks
I fabricate and weld custom wheel chairs. Very good information. P4X medical.
Thanks for the great video, for those of us who dont have such fancy tig welders, could you make a video to show what difference there would be with a welder with say only square-wave and not adjustable frequency. How would the finish be different?
Love the videos definitely one of my favorite channels on here you spread so much helpful knowledge I just wanted to thank you for doing what you do .
Beautiful welds as always but those guys should seriously consider getting a mandrel bender!
mandrel benders are not gonna cut it. pie cuts are intended for dual axis or close radius bends.. things can be done with pie cuts that a mandrel cant touch.. in addition its fairly desirable of a look in the car community.
mandrel benders are not gonna cut it. pie cuts are intended for dual axis or close radius bends.. things can be done with pie cuts that a mandrel cant touch.. in addition its fairly desirable of a look in the car community.
mandrel benders are not gonna cut it. pie cuts are intended for dual axis or close radius bends.. things can be done with pie cuts that a mandrel cant touch.. in addition its fairly desirable of a look in the car community.
+Matt Gardner,
Hi Matt, I can understand the aesthetics of seeing a nice tig weld under the hood but I'm looking at it from a practical standpoint of pumping out product as fast as possible for the least amount of cost. The 4 inch intake that I have on my vehicle was mandrel bent with very tight 90 degree angles. After working in a shop that had an industrial bender capable of working a 20 foot tube, bending a dual axis was not an issue.
dang Jody, I missed you bro! another great video. I've seen this done with stainless for exhaust set-ups and that rainbow effect is killer! happy new year to you.
This is awesome, I'd love to see you do more automotive welding, since its what I do, also it would be awesome to see you do a stainless exhaust header.
Hey jody. I really like the video. It's a good example of the challenges that a welder needs to overcome sometimes (no car to align the part after tacking). I've never welded using a triangle wave form before. I was just wondering if the AC balance is not 50/50, does the difference in time that the current takes to reach it's peak (it would spend more time getting from zero to max current on the negative side than the positive for anything less than 50% cleaning) have a noticeable effect on the weld itself. Sorry if this sounds confusing, I wish I could draw it.
use a manfrotto magic arm that has a clamp attached instead of stabilizing the piece with blocks. To use: clamp the manfrotto to the piece, turn the piece to be welded in any direction you want, hold the piece steady while you throw the lever on the manfrotto and instantly the manfrotto locks and holds that position rock solid until you release the locking arm.
www.bhphotovideo.com/bnh/controller/home?
manfrotto -
A=details&O=&Q=&ap=y&c3api=1876%2C%7Bcreative%7D%2C%7Bkeyword%7D&gclid=CjwKCAjw0qLOBRBUEiwAMG5xMCR1dY4MPxlSXuAoaeBGeaYH9hW9vtFpk3pgh7L8NjrZoAkh89fcEhoCfvkQAvD_BwE&is=REG&m=Y&sku=554346
thanks jodi et.al. > the 'job world' application & tech discussion monitoring. stainless header builders use a sturdy mock holding jig; maybe for something similar to the aluminum tube of the video a simple cardboard start / finish point fixture... granted the technique and expertise that went into its completion.
Great video you made this very easy to understand
Nice video! Thanks for including metric too!
I'd love to hear about the reasons Roy prefers a standard cup over a gas lens. I've never used anything but gas lens setups for the time I've done TIG welding and never really considered regular setups.
Hey can you do video about the differences and strengths and limitations between air cooled and water-cooled machines always wanted to get an experts opinion about that.
Why not purge weld it specially with the irregular fit with large gaps
How about some video of the tubing on the inside Looks great
Another excellent video. Thank you. Look forward to the waveform video.
As I do a lot more than just welding and fabricating stuff, I'll throw out a pointer to you guys who want to make automotive IC or other piping. If you need a big bend of say 90 degrees or more and decide to make it like this, do as in the video and make 5-6-7 pie cuts, not just 2. You might think that it holds the same area and such, but I have a flowbench in my shop and have tested it. You do NOT want any angle for each cut steeper than 25 degrees included, period. Example: I did make a cut in a 2.5" pipe and angled the pipe at about 45 degrees. It promptly flowed just a tiny bit more than a straight piece of 1.875" pipe. A radius bend - which is what you make with enough evenly spaced pie cuts - loses in the region of 1.5% over a similarly sized straight piping.
Very knowledgeable at your skill . Keep the tutorials comming..
Another great vid I would like to see a vid on s/s pulsed mig. Keep them coming only watch your welding channel
Hey I do a lot of SS pulsed mig welding where I work. I could help you with some tips if you want?
+Chris Porter
Hey, Chris. I used an argon purge on some scd 80 4". I taped the ends and shoved an argon hose in a hole. I still got sugar on my inside weld. What's up with that?
Awesome work, thanks for taking the time to do this. I'm learning a lot!
Howdy. I'm a new subscriber and i like what you're doing here. Keep up the great work!
Can you do a series on Structural welds with Dual Shield? I'm just getting my start in the steel industry. We use mostly A36 mild steel. Mostly wide beams and flat plate, some square tube. Very interested to see what you can teach me so that I can pass company certification tests.
Thanks for having this channel. I will be watching more of your videos as time permits.
Cheers!
Great Tig welding aluminum..Thumbs up weldingtipsandtricks
I thank you devote the time to
share tour experience and I wish
you a year full of heath and
prosperity for you to continúe
sharing you knowledge
Excellent job. Would a job like this get extra billing over a regular job in the shop based on the difficulty in positioning with all the pie cuts?
Jodi, amazing videos. Thank you very much for the great content.
Jody, another of your teaching efforts for my interest. can a square wave transformer machine (Miller 180SD) create the cleaning action you describe for your tacking process on these pie cuts? i really appreciate your comments on Roy's
excellent approach for his weld technique on the tube welds.
So, with your math, that weld job was around $300.
Pretty expensive, but damn that's alot of work! Great job.