Alternatives to welding aluminum for puppet stage?

[cadcoke4]

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

[c wagner]

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.

[SignWave]

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/ProductsServices/Adhesives/LORDStructuralAdhesives/tabid/3383/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.

[cadcoke4]

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

Joe Dunfee

[fun4now]

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

[El Guanche]

Try JB Weld

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