- 1). Clean the repair area of the aluminum with a wire brush to remove grime and dirt. Use a shop towel to remove lubricants that may be present.
- 2). Attach the alligator clip of the welder ground cable to the work area or a work bench. Turn on the welding machine and set it to your desired amperage.
- 3). Put on the welding helmet and insulated gloves. Position yourself above the work area.
- 4). Hold the welder tungsten at a 70-degree angle to the piece being welded and about 1/4 inch from the surface. Start a weld pool in the aluminum with the tungsten at the beginning of the weld. A weld pool is a puddle of metal that forms after being heated.
- 5). Hold the filler metal at a 15-degree angle and begin to dab into the weld pool. Drag the weld pool along the length of the repair area and continuously fill with filler metal until you reach the end of the area being welded.
- 6). Allow the aluminum to cool. Clean the weld with a wire brush to remove weld splatter and rough edges. Wipe the surface clean with a shop towel. The finished weld may be painted if desired.
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