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Alternatives to welding aluminum for puppet stage?

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  • Alternatives to welding aluminum for puppet stage?

    I just joined this forum because I was looking for alternatives to welding for a puppet stage project I have in mind. I didn't know where else to go.

    I know a shop where the weld aluminum tube on a regular basis. In my case, the heaviest material I will want to use is 1x1 x .060"square tubing (probably .030 wall if I can). But, they say that welding the thin-wall stuff is a problem because the process tends to blast away the base material.

    So, I am looking for alternatives to welding. Here are some options I am considering, but am unsure what will be the best choice;

    - Using flat "L" brackets or triangular gussets and riveting
    those to the frame.
    - Same as above, but epoxying to the frame.
    - Fiberglassing the joint.

    Any comments or other ideas?


    Joe Dunfee

  • #2
    Originally posted by cadcoke4 View Post
    So, I am looking for alternatives to welding. Here are some options I am considering, but am unsure what will be the best choice;

    - Using flat "L" brackets or triangular gussets and riveting
    those to the frame.
    - Same as above, but epoxying to the frame.
    - Fiberglassing the joint.

    Any comments or other ideas?


    Joe Dunfee
    Riveting will work and should be pretty cost effective. There is also a transportation grade two part glue or epoxy that I use at work, it would be more than enough in this application. I don't know what the name of it is but I can let you know when I go back to work on Jan 2.
    at home:
    2012 325 Trailblazer EFI with Excel power
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    at work:
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    Retired:Shopmaster 300 with a HF-251

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    • #3
      sticky situation...

      you could use adhesives.
      try searching out a company called LORD adhesives. they make glues and two parts for everything under the sun and they stick like $hit on a wool blanket.
      http://www.lordfulfillment.com/upload/SG1006.pdf
      http://www.lord.com/Home/ProductsSer...3/Default.aspx
      if you make some corner gussets and use some clamps you could glue your stage together and is would, im sure, hold up very well.

      I wouldnt suggest fiberglass though. its way messier than you want to know. and a pain in the a$$ to deal with.. it stinks, its sticky,frustrating, and expensive..

      as for "blowing out the base metal" that is indicative of skill level..
      A good TIG man shold be able to weld pop cans together on a regular basis...

      ASK ENGLOID on the motorsports side... he is very much experienced.
      Last edited by SignWave; 12-24-2007, 01:17 PM.
      Will it weld? I loooove electricity!

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      • #4
        Thanks for the replies. I think I am going to go with epoxy.

        Joe Dunfee

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        • #5
          it seems strange to join a welding forum to find an alternative to welding. but you could use a low heat soder/weld material. try these guys
          http://www.aladdin3in1.com/
          like said above TIG would be a good choice but MIG may not work out so well on that thin. i would TIG weld it but you could try the stuff aladin has as another option, or go with a 2 part epoxy.
          good luck
          thanks for the help
          ......or..........
          hope i helped
          sigpic
          feel free to shoot me an e-mail direct i have time to chat. james@newyorkmetalart.com
          summer is here, plant a tree. if you don't have space or time to plant one sponsor some one else to plant one for you. a tree is an investment in our planet, help it out.
          JAMES

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          • #6
            Try JB Weld

            http://jbweld.net/products/index.php

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