There are a lot of technical tips and tricks to welding that seem logical, but if nobody every pointed them out then you might never think of it. Instead, you might spend countless hours trying, and failing, to build the parts and pieces you want to at home. Welding aluminum can be really rewarding and fun, but sometimes it can also be really frustrating. A lot of folks find that after welding up an expansion tank, overflow, or fuel cell, putting in the bungs and fittings can be a real challenge.
When the flange on a fitting or bung is 3-10 times the thickness of the material you built the tank from, it can get really challenging to weld them together in a way that looks nice, is strong, and doesn’t leak. But here is some real world technique that can help you on your own projects. Check it out.
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