The Top DSM Community on the Web

For 1990-1999 Mitsubishi Eclipse, Eagle Talon, Plymouth Laser, and Galant VR-4 Owners. Log in to remove most ads.

Please Support RTM Racing
Please Support Morrison Fabrication

overflow tank out of aluminum

This site may earn a commission from merchant
affiliate links, including eBay, Amazon, and others.

This site may earn a commission from merchant affiliate links, including eBay, Amazon, and others.

Gamble97

15+ Year Contributor
2,642
63
Jan 3, 2006
small town, Illinois
Made this out of .063 aluminum. Plasma cut out all 8 pieces and took my sweet ass time cutting, measuring and trying to get everything as close to my measurements as possible. Not really going off anything just memory.
Well needless to say it welded up like complete shit. I brushed it, used acetone, but for the life of me it just wouldn't weld really well. I'm wondering if using the belt sander contaminated the metal at all?
Really made me made, so I finished welding all but one piece and decide to take a flap disc to the entire thing. Think it will still hold up? I know everyone says your not supposed to grind down aluminum welds but I've seen people do it for making dashboards and making it all look like once piece.
I think I might just weld over the entire thing again just to be sure it will hold. Then sandblast it and paint it or just sell it to someone that wants to powdercoat it.

Thoughts/ideas/advice??

This is where I stopped tonight.
You must be logged in to view this image or video.

You must be logged in to view this image or video.
 
As long as its water tight its fine, its not like its under any amount of pressure. I made one out of stainless that looked identical and I ended up scrapping the idea. Not any reason really, just didn't like it.
 
Don't try to weld plasma cut edges and expect them to look nice. The plasma cutter screws up the aluminum. Use a shear or band saw. BTW, nice design. :)
 
From what I remember it looked something like this LOL.
I ordered that 8" shear from harbor freight so whenever it shows up (in june from major back order) hopefully it will be nice and not suck
 
The plasma cutter is the main issue. As long as the machine is setup right, and you grind the cut edge and clean the parts it should weld fine.

The reason you do not want to grind down aluminum welds is in the welding process affects the temper of the aluminum. So the weld is the strong point and when the aluminum fails it should be just along side the weld, if it cracks down the middle of the weld it was not welded properly.

I would think for a non pressurized non structural piece it would be fine.
 
The reason you do not want to grind down aluminum welds is in the welding process affects the temper of the aluminum. So the weld is the strong point and when the aluminum fails it should be just along side the weld, if it cracks down the middle of the weld it was not welded properly.

I would think for a non pressurized non structural piece it would be fine.

FOr most metals this rule is true, but on aluminum the weld is actually one of the weakest parts (which is why you want to leave as much there as possible) the reason being the additives to the aluminum tomake it blend with the other alloys it can be used on causes it to be weaker than the billet/sheet/cast you're welding too.

Most metals when "tested" have to break in the HAZ (heat affected zone just outside the weld) where as aluminum can bend but shouldn't break if the weld is proiperly done. I don't know ALL of the reasons but i know the silicate content in the weld rod is part of it. YOu can grind about any other steel weld you want because as you stated it is the strongest area even when "dressed" but aluminum depends on having every single bit of that filler to maintane it's strength
 
Support Vendors who Support the DSM Community
Boosted Fabrication ECM Tuning ExtremePSI Fuel Injector Clinic Innovation Products Jacks Transmissions JNZ Tuning Kiggly Racing Morrison Fabrications MyMitsubishiStore.com RixRacing RockAuto RTM Racing STM Tuned

Latest posts

Build Thread Updates

Vendor Updates

Latest Classifieds

Back
Top