Welding aluminum

[Gomer pyle]

I am a hobbies/farm repair. I have an older Snap-On (rebranded Systematics) power source (100% duty cycle at 300 amps) with a Miller wire feed. It does an awesome job. It is my first welder.
I have a project coming up, where I need to weld a bunch of aluminum. I may never do anymore, but having a tool and knowledge is always handy.
Per manufacturer, in order to put a spool gun on my power source, I have to get a different box($1200 for controller and spool gun). This setup will only work on my machine. I don’t mind the price, but keep thinking about the age of my machine.
Any other ideas/opinions? I’m not against another machine but don’t think I would sell mine. The project coming up would be mostly 1/4” square tubing with a little bit of 3/8” flat plate.

 

[RNeumann]

For $1200 you can get something like the Lincoln 180 mig machine AND the Lincoln 100SP spool gun.

If you can step up to the Lincoln MP210 that is a nice machine. They also make the 180 in dual voltage 120/240, and or with TIG.

I tend to agree with you- spending that much on the old machine probably isn’t the best investment.

 

[Gomer pyle]

I do fear the duty cycle with the newer smaller machines. I have no patience. Lol.

 

[Gomer pyle]

I do have a Lincoln 140 I bought to use with a generator for portability on the farm. I believe the 100sg will work on it but I can’t find any info on material thickness.

 

[Fuddy1952]

This may not help at all...but I had to weld some aluminum and some of these alumafix rods you can order from eBay. Thinner aluminum I use a propane touch, thicker I used oxy/acetylene like I was brazing.
As I say, it all depends I'm sure at what level this project is for, strength, professionalism, etc.
For what I was doing...it worked.

 

[Motorboatin]

For one job I would just rent a welder

 

[yomax4]

You could always try running aluminum through your current feeder and gun. Teflon liner, U-groove feed rolls, 45 degree neck, 10' gun and 5356 wire. It's doable.

 

[spitter]

If the job pays for the tool and you still make a decent profit id call it a wash. That spool gun will always come in handy you'll probably use it more than you think. Going from 300 amps to 180 don,t make good sense to me but what do I know I'm a gluten for old transformer machines not a hole heap load to break.:drink:

 

[Ritothebull]

You could always try running aluminum through your current feeder and gun. Teflon liner, U-groove feed rolls, 45 degree neck, 10' gun and 5356 wire. It's doable.

This is what I would do, running a spool gun on aluminum can be a ***** for a beginner and you won't get far with those little Lincoln machines on 1/4'' and 3/8'' aluminum.

 

[jaxs]

If you are looking to buy new equipment and expand your capabilities,have you considered tig? Can you run tig off your power source? Another consideration is the ampacity required for 300 amp transformer. I believe you can buy a multi-purpose inverter machine and accessories for $1200.