The Turbo 3500 F23 swap (Page 14/80)
ericjon262 DEC 30, 11:57 PM

quote
Originally posted by Corpsmen Ed:

Holy crap, dude. This build is awesome. Now you have me thinking of doing something crazy different for my swap.



Thanks!

I'm getting ready to start modding the Upper intake manifold to accept a 75 mm LS1 throttle body, and hopefully increase flow and velocity.
Cliff Pennock DEC 31, 05:35 AM
Thread title changed per OP's request.
ericjon262 DEC 31, 10:31 AM
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[This message has been edited by ericjon262 (edited 09-11-2022).]

ericjon262 JAN 02, 12:59 AM
who said you can't mig weld aluminum without a spool gun!



but, in all fairness, it's a royal pain without one, I'm going to try to get one now though!

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Fiero Owner's group on 60degreeV6.com

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Joseph Upson JAN 02, 07:12 AM

quote
Originally posted by ericjon262:

who said you can't mig weld aluminum without a spool gun!

but, in all fairness, it's a royal pain without one, I'm going to try to get one now though!




You can, it's just very difficult with thin wire (.023) and a Mig unit setup for steel wire. During the purchase of a replacement hose and trigger, I discovered there was a special aluminum welding kit and purchased it. I don't have it in front of me but the most unique thing about it is the nylon liner that is to be inserted in the hose in place of the steel spiral liner to reduce drag on the wire that causes it to wod up in the unit at the feed point. I've had the kit which came with a good size spool and slag brush and some other things I can't recall but I have yet to try and use it. I did attempt it long ago with the standard setup and as stated it was a horrible mess, the unit jammed easily.

What you have displayed is very encouraging, I just don't have any aluminum welding jobs at the moment to try out the aluminum welding kit and yes I have a tank of the proper shielding gas for it. Heck I might make my own intercooler water tank if it works out okay.

[This message has been edited by Joseph Upson (edited 01-03-2013).]

fieroguru JAN 02, 08:20 AM

quote
Originally posted by ericjon262:

who said you can't mig weld aluminum without a spool gun!

but, in all fairness, it's a royal pain without one, I'm going to try to get one now though!




Here is my aluminum mig weld w/o a spool gun!


I used the aluminum conversion kit with the plastic liner and non-grooved rollers. The biggest challenge is when the wire doesn't push, reduce the roller tension vs. making it tighter. The issue with the feed is almost always too much roller pressure deforming the aluminum so when it get to the tip it can't fit through the hole. I did all my welding with .035 wire, but I did pick up a couple spools and tips of .045 to see if it works better. If I didn't like my welder so much (ProMig 175) I would buy a new one with a spool gun, but I like it and want to keep it for now. Maybe I will try adapting a spool gun to this welded some day when I need to do more aluminum welding.
Joseph Upson JAN 02, 09:11 AM
The thickness of the wire is more a function of your welder's amp rating. I run a 110 v 90/100 amp unit for versatility so .045 is pushing it if an extension cord is involved. The downside of a spool gun is that it would have been impossible for me to do some of the in car mock ups I did for close tolerance clearance.
ericjon262 JAN 02, 12:54 PM

quote
Originally posted by fieroguru:


Here is my aluminum mig weld w/o a spool gun!


I used the aluminum conversion kit with the plastic liner and non-grooved rollers. The biggest challenge is when the wire doesn't push, reduce the roller tension vs. making it tighter. The issue with the feed is almost always too much roller pressure deforming the aluminum so when it get to the tip it can't fit through the hole. I did all my welding with .035 wire, but I did pick up a couple spools and tips of .045 to see if it works better. If I didn't like my welder so much (ProMig 175) I would buy a new one with a spool gun, but I like it and want to keep it for now. Maybe I will try adapting a spool gun to this welded some day when I need to do more aluminum welding.



Got a part number for the conversion kit? I have a Pro Mig 180 and that sounds a whole lot cheaper than a spool gun! ($250)

Thanks-

Eric
Justinbart JAN 02, 01:11 PM
I tried to mig aluminum once. It kept balling up on the roller anytime the wire would hit the surface I was welding. I looked into the kit for ~$70 but never got it. I've always heard you really need a spool gun for mig welding aluminum. looked into spool guns and I decided I would rather put that money towards a nice TIG setup.

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Turbo 3800 E85 F23 5spd spec5
11.17@132.6

Joseph Upson JAN 02, 01:31 PM
http://www.htpweld.com/prod.../accessories/a5.html

Scroll down to the aluminum kit. Glad I looked over the intro as it has some pointers that I was not aware of. I also hope that I didn't toss the nozzle that came with it on the gun for general purpose use. Now that I think about it, since I got the new gun and kit at the same time I'm sure I didn't. I certainly wasn't aware of the need for higher gas pressure.