How to Gas Weld Aluminium

A rough guide to welding aluminium sheet using oxy acetylene gas.
Special parts required:
Type 5 gas nozzle
Aluminium flux
Blue or special green lens - blue lens are hard to find. For a cheap alternative search for 'CV85/5w' lens.
Other gas welding aluminium videos are available on this channel:
• Project Etceterini - P...
More complex aluminium welding tasks are also due in the near future.
Thanks for watching!

[@N8-T]

Pretty cool. I recently bought an old dairy farm. Found out the the old farmer who used to own it was a welder in WW2. Gas welded aluminum on airframes. Then i started noticing all the things around the farm made of aluminum. That and irrigation pipe repair. All done by the good old boy. Ontop of all that, hes 97 going on 98. Lives in a local retirement home. Been trying to make plans with him to get him out to his old farm one more time.

[@GasoliniASMR]

Thanks. Lovely story - hope you get the old boy out there again!

[@myselfremade]

Nate whereabouts are you located?

[@N8-T]

@@myselfremade, North Idaho

[@cs-gj3yf]

you ever get him out?

[@N8-T]

@@cs-gj3yf, I did, I think last September, him and his second oldest daughter and his son in law came out here, stayed for about an hour, did a little looking around. Then showed me pictures of what it used to look like and also gave me an old picture of the place. Was good to have him out

[@redpost2380]

10/10 for for getting in there and doing it. mig/tig suppliers should buy this video to promote the modern electronic machines. 100 years ago it was all done with Oxy acet, so it can be done and you become a true craftsman when you master this skill

[@GasoliniASMR]

Thanks! I tried my best and am getting better.....

[@Konadawg99]

It’s tough to convey with words how difficult it is to actually do what he’s doing. Well done man

[@GasoliniASMR]

Thanks. I muddled through and slowly got a little better

[@davethomas3493]

Excellent, thanks. Straight to the point, no waffle or life stories, cheers 🍻

[@GasoliniASMR]

cheers Dave!

[@uncontrollabledogs3791]

Yes. No BS at all.

[@jared1228]

I'm not a welder but trying to learn. Thank you for providing this video to help me along the way.

[@GasoliniASMR]

No problem. Hope it works for you

[@chhindz]

Have owned gas welder for decades, nice to know I can do aluminum with what I have, Just need an English wheel.

[@eurobeatmachinist732]

This is very hard to do, you did great! My grandpa uses aluminium stick welding rods instead of strips of ally

[@GasoliniASMR]

Thanks. I'm getting there!

[@jondavidmcnabb]

Excellent video, i love the extreme detail! Seriously debunked alot of the other videos i have seen.

[@mpireoutdoors5274]

Helpful. Appreciate the no-bullshit approach. Make more on other metalwork/shopwork with the same format.

[@GasoliniASMR]

Thanks. I have a few other similar videos on shaping aluminium and building a car from scratch

[@mpireoutdoors5274]

@@GasoliniASMR will check it out when I have time. Any experience with those aluminium filler rods? For us boys without a welding machine or off grid

[@acrizona]

Cannot miss the green Piper 'P2' in the background. Outstanding !!!

[@GasoliniASMR]

Thank you!

[@joaodias7556]

Thank you for the detail. Best regards from Lisboa.

[@Professorclown]

Artificer in action! Some great craftwork there - so good to see these (rare) skills!

[@GasoliniASMR]

Thanks Professor

[@bpr50]

Thank you,great video.

[@Ricopolico]

Thanks for watching? No, no, no, thanks for showing! Always have been waiting for a TIG to join aluminum. Now I don't have an excuse.

[@GasoliniASMR]

Good luck!

[@qayskaro2116]

I just got my cutting torch very excited about it i’ve learned a lot from this video can’t wait till I try it.

[@Airon79]

You're going to need a welding tip if you want to weld though but a cutting torch is still handy .

[@cristianpopescu78]

Amazing! Thanks!This stronger than TIG

[@65bellett]

Great video!! Thanks for sharing.

[@GasoliniASMR]

Thanks!

[@utsports]

That is a good Aluminum weld,the Aluminum that you cut,and used with the Flux, fused into the other piece of Aluminum

[@bobmartin6055]

Very helpful!

[@Dogleg1957]

Good learning techniques wished I had learned. My dad never welded aluminum so I was self taught.

[@GasoliniASMR]

the best way to learn!

[@daos3300]

gas welding ally. there's a skill you don't see often these days. for cleaner, smaller welds you could reduce your heat and use a much narrower filler strip.

[@GasoliniASMR]

Thanks. All that grinding and finishing off is taking a long time!

[@zachcrowl8504]

Been thinking about giving oxy/ace welding a try. I’m not trying to be a professional or anything mainly just for hobby stuff but I want to learn to weld and this seems like the hardest way but it’s the least involved way. I don’t need a fancy machine or anything. If I want to weld aluminum i need gas cylinders anyway. I can cut metal with the torch as well

[@GasoliniASMR]

It's tricky but worth a try. Need time and patience

[@fantastiqtechnalogysiklls3358]

Good work

[@GasoliniASMR]

Thanks

[@SAD-rv]

Nice 👍

[@fantastiqtechnalogysiklls3358]

Very nice

[@GasoliniASMR]

Cheers

[@michaelallen1432]

Im not sure what lenses your using but the manufacturer of the didymium purple lenses i use told me that the cobalt or didymium lenses alone ate not sufficirnt eye protection for welding. Thry said yo back them up with the standard green lenses. I use either a #3 or #5. Edit: I see later that you said you're using a special aluminum welding lens. 👍

[@GasoliniASMR]

Thanks for the info. Much appreciated

[@mazdarxrx]

you have skill master

[@GasoliniASMR]

cheers

[@uncontrollabledogs3791]

Excellent work with that torch and no BS or $hit music.

[@GasoliniASMR]

Thanks!

[@0ldGrumpyBastard]

Don't use a steel brush to clean AL, you just contaminate the metal. Also, don't preheat your filler metal. Instead, use it to cool your puddle in an effort to manage the excessive heat you're causing by not using a smaller tip). Cheers!

[@GasoliniASMR]

Thanks for tip. I'm going to do some experimenting soon, would you suggest a no.2 tip instead of a no.5?

[@cristianpopescu78]

Brass brush is good, as well,litlle cooper into aluminium make it better.

[@iankidd6654]

If it is similar to Aluminum MIG welding it is best to clean with Acetone before and after wire brushing with an SS brush

[@jtbmetaldesigns]

Well that’s all gas welding is. It’s heat management. But to me it’s more versatile than TIG,MIG, and stick. Arc welding heat management is most control of amperage. The gas torch not only allows tip size change but you can also change flame chemistry from neutral, carburizing and oxidation for many types of heat treatments. Plus there is the cutting option for steel.

[@carlosgavino6874]

No no no no no thank you sir for sharing and helping me learn

[@meassavuth4649]

Hello sir , do you know can we use the cooking gas for welding aluminum ? Can we use only one cooking gas or need to add ogygen ? Thanks ,

[@GasoliniASMR]

Hello. I don't think cooking gas will work as it needs to be very high temperature. In some countries calcium carbide can be used to make acetelyne gas but this can be potentially dangerous.

[@bengkel.panggilan.24.malang]

👍😍😍

[@thedoingnotthedone.6292]

Are you using blue just on the camera and green in your visor? Interesting to see that the green is ok. How much practice did it take until you could make a good join and how much more again until you'd risk some panels you'd shape under the torch?

[@GasoliniASMR]

I have some old blue welding glasses that I use for the camera and my mask is green. The green lens is a special type of green - cv85/5w that works for aluminium welding. It took quite a lot of practice before I risked shaped panels, however my welding suddenly improved as soon as I used shaped panels!

[@KamarulAzlanAhlengChai]

Can use this method to filling dent hole in aluminium motorcycle swing arm ?

[@GasoliniASMR]

I have used this method for filling in aluminium parts but wouldn't risk it on a structural part. Might be best to use a tig welder

[@davemcnair1569]

old volvo and mk 1 cf got be worth a look thanks where do you get blye lens from

[@GasoliniASMR]

Blue lens are hard to buy new but can be found second hand. Next best is special green lens - CV85/5w Shade 5 These should be available for about £15 or £35 with headcap.

[@davemcnair1569]

@@GasoliniASMR thank you

[@dougjones4987]

Great video, thanks for posting, what kind of torch is that?

[@GasoliniASMR]

Just a normal 'hobby' size gas torch. A number 5 nozzle, although that may be a touch large

[@AxelP33]

Where did you get the blue filter ?

[@GasoliniASMR]

I got the blue filter on some old lenses that I bought off ebay. I don't think blue lenses are still made. Possibly because they are not quite as safe as the green ones.

[@laurentmarion165]

Très bonne vidéo, dommage que je ne l'ai pas vue avant d'emmener ma pièce à souder , j'aurais économisé 30€.

[@James-hg5tk]

Would you trust this method for aluminum tubing for boost?

[@GasoliniASMR]

Not too sure. I think I'd go with tig welding for that application.

[@James-hg5tk]

Gasolini cool thank you!

[@michaelallen1432]

You weld my my grandmother! 😂🤣 Actually, my grandmother didn't weld, but anyone who knows WWII history will get the joke.

[@natanaelmelo9481]

What flux do you use for aluminum welding?

[@GasoliniASMR]

I use Super 6 Aluminium welding flux (Part no. 7520) or Sif Flux No.36

[@oscarergina3029]

What kind of liquid/chemical you use in aluminum rod /plate, thank you

[@GasoliniASMR]

Hello Oscar. I use a powder mixed with water to make the flux. SIF products seem to work well.

[@kevinragsdale6256]

what does the flux do?

[@GasoliniASMR]

the flux stops dirt and impurities getting into the molten weld, otherwise it will blow holes easily.

[@iankidd6654]

Great video. Can you use Oxy/ LPG to weld Aluminum, as I know you cannot use Oxy/ LPG to weld steel for some reason

[@GasoliniASMR]

Thanks Ian. I don't think LPG is suitable in this situation as it doesn't provide a clean shield and impurities could get in to the weld.

[@christophersimmins3181]

Answer as to why you cant fusion weld steel with Oxy -LPG...An oxy -Act flame has a temp of 3,100 degrees f.... while a Oxy LPG flame temp is 2,700 degrees f. If you wish to undertake fusion weld of steel successfully , its temp must be raised above its fusion melting point ...The oxy -act flame also provides a gaseous shield to the atmosphere. This helps reduce rapid surface oxidation and producing a crap weld. Depending on the chemical composition of steel ,it will generally melt around 2,800 F.

[@pabloricardodetarragon2649]

@@GasoliniASMR LPG oxygen welds perfectly aluminium. You must adjust a neutral flame, and LPG needs lots of oxygen to burn cleanly.

[@BoneJangle]

Time to get good at aluminum

[@christusigboekwe6395]

I've been trying to balance my flame but it just keeps going off... So sad

[@Wolfeboy212]

Let the tip heat up with a lower oxygen flow first. Too much oxygen is almost always why it goes out, so add it slowly, and dont be afraid to add more gas/acetylene. If you're getting a very high-pitched hiss instead of a ripping sound that's a sign of too much oxygen as well.

[@millennium3778]

What name this rod aluminium … flat rod aluminium ?

[@GasoliniASMR]

the rod is cut off the same sheet that I am working on. It is 1050A sheet 1.5mm thick.

[@sheilamclaughlin963]

Should of hammered on it while hot, probably work better, steel it does

[@GasoliniASMR]

thanks for the tip. Will try it hot next time

[@whtwolf100]

Strength test? All that oxidation cannot be good

[@GasoliniASMR]

Good point. I'm thinking of doing an updated video in the future now my welds are a little better. Maybe I'll try some strength tests.

[@SolidProofEngineer]

An old Bedford nose...

[@TheCarlhungness]

AM not trying to be critical, but a #5 nozzle from one manufacturer is totally different than a #5 from another so we don't know WHAT SIZE torch tip to use, precisely. I understand it ought to be about .043". Next not sure what pressure you used on Oxy or acetylene..I think it is about 1 1/2 lbs. Then, we don't know what thickness material you are welding.the thicker the easier, the thinner is more difficult..your intentions are marvelous, but some more tech advice would help.

[@GasoliniASMR]

Fair points! I did try to question some professionals to get some more exact details on nozzle sizes, amongst other things, but didn't get any answers. Whenever I questioned those in the welding trade they just said it was 'impossible' to gas weld or would take years of practice and that an amateur would never be able to make a car body from aluminium or gas weld it. Luckily I ignored them and so I thought I'd try and do a video to try and encourage people to get out there and do it themselves. I am looking for a real pro who is willing to let me video and question them about gas welding but haven't found one yet.

[@zooniethelazoon]

Hi Gasolini, hope this finds you. I'm with the Piper Owners Club and was wondering if you're known to us? Could you reply to this comment please, thanks.

[@GasoliniASMR]

Hi Mark. Yes, I haven't done much for a few years but should be back on the Piper soon!

[@vijaychawariya3402]

Aap. Contety. Btao. Karo. Kitna. Oxcijan. Or. Kitna. Corbonet. Chhodni. Hea. Bol. Ke. Batao. Karo. Kese. Karna. Hea

[@GasoliniASMR]

slappity clittity

[@christianhage1511]

Tried this with zero success. I'm too heavy handed I guess. There is never a pool, and all of a sudden the complete part just melts away. Also don't seem to be able to keep the heat local, it all does nothing then all of a sudden, all just melts away. Got this flux, tried different ways, no avail :( I wish someone could teach me this. I don't seem to be able to hack it from a video

[@christianhage1511]

@@prototribal4659 That makes perfect sense. After your comment I can see how he's going in with more focussed heat. I've been way slower. Well thank you, will give this another try :)

[@locoartzplanes7655]

I’m sorry but this is not good aluminum welding at all! This would be good if all you ever had was an Oxy/Ac set up and never invested a $ into learning a trade. Sorry better luck next time. Essentially your melting dirty metal together… there is no welding here.

[@GasoliniASMR]

What I was trying to bypass was the 'perfect weld' snobbery that told me I'd never be able to gas weld aluminium or build my own car. Repeatedly. I used to believe those professionals who told me it was 'impossible' for an amateur to build an aluminium car from scratch then I thought I'd give it a go myself and hey presto, I managed to build my own car as it turned out. Had I gone to the pros it would have cost £200,000 and taken twenty years, with them making a fuss every month going on about how difficult the work is. This video is purely to try and encourage people to go and try something themselves. Every day I thank god I didn't listen to the many people like you, and there's no need to apologise, as at the end of the day I followed my dreams and I managed to build my own car from scratch.

[@andykerr3803]

​@@GasoliniASMRAgreed. Don't dismiss aluminum solder also. For any metal, the less heat the better, especially high carbon steels. Brazing, soldering create excellent bonds. The airline industry uses glue, not welds an high tensile aluminum alloys. A "pretty" weld can be a very dangerous thing 😂

[@hollygaag895]

There is so much wrong wit this video

[@GasoliniASMR]

I'm looking to make another video on gas welding aluminium from the point of view of an experienced welder. If there is an experienced welder in the UK that is willing to give up some time to demonstrate how they gas weld aluminium, please get in touch!

[@nickmitchell7925]

@@GasoliniASMR It's a great tutorial and much appreciated. Pay no attention to the twats.

[@dougjones4987]

We'll be here waiting for your video

[@jtbmetaldesigns]

@Holly Gaag No, the only wrong thing here is you. I bet you beat every level of every video game you play. Too bad you haven’t figured out real life skills yet.

[@Militarycollector]

Congratulations you just ruined a perfectly good sheet of aluminum

[@sazzadhossains4329]

Work policy not good.please change the methode..

[@jtbmetaldesigns]

Seriously, what the hell you talking about? Are you trying to make a point?

[@modoc852]

Hate these Charlie Chaplin movies