In this video, I used a Diversion™ 180 TIG welder to create an aluminum air pan for a ’48 F1 Ford pickup truck. In this video, you’ll see that I also demonstrate how to weld with different material thicknesses. As always, make sure you start with clean material. I am using 5356 aluminum filler for this particular project, but cut it in half for easier use. When you’re welding with materials with different thicknesses, the Diversion™ 180 is an ideal welder for the DIYer because of its ability to let you easily dial in the material type and thickness on the machine. When working with thinner aluminum material, consider skipping welds to prevent warpage and evenly distribute the heat. An example of skip welding would be making a one-in weld and then skipping six-inches before making the next one-in weld. When skip welding, try using silicone filler to create a better seal. Another tip to remember when using different material thicknesses is to preheat. In this video, the ½-in plate is outside maximum capability of machine. To get around it, preheat the thicker material to make it easier for puddle to wet out.
TIG Commercial Product Manager