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Thread: Winter Projects

  1. #1
    Stephen's Avatar
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    Default Winter Projects

    I'm running out of major modification projects, so I'm doing more anal stuff.

    Last winter I replaced both lower longerons. I was not happy with the look after I did the 22 inch stretch. Now it looks much straighter.

    Replace longerons.jpg
    Replace longerons.jpg

    This Fall I've been making new doors. The old doors were too leaky. I used 3/4" square aluminum tubing.

    New Doors.jpg
    Last edited by Stephen; 10-29-2022 at 11:48 PM.
    "You can only tie the record for flying low."

  2. #2
    Old3pacer's Avatar
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    Default Re: Winter Projects

    Looks very nice!
    craftsmanship!

  3. #3
    Administrator Steve Pierce's Avatar
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    Default Re: Winter Projects

    Looks nice. How does the weight compare to the originals?

  4. #4
    RobertC's Avatar
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    Default Re: Winter Projects

    Quote Originally Posted by Stephen View Post
    I was not happy


    Yes, I know that.

  5. #5
    Stephen's Avatar
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    Default Re: Winter Projects

    Quote Originally Posted by RobertC View Post
    Yes, I know that.
    How is it that you know me so well?

    Happy now...I cut 2 pounds weight of each door. Now I can go back to having my dessert again.
    "You can only tie the record for flying low."

  6. #6
    Stephen's Avatar
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    Default Re: Winter Projects

    I learned two new tricks on this job.

    1. Aluminum brazing is easy and strong. I tested the braze by putting two aluminum square tubes together in a tee. Then putting it in a vice and taking a large hammer to it. The weld held but the aluminum square tube eventually tore open

    2. Preval Paint Sprayer. Wow. Just pour your paint into their 1/2 pint jar, screw on the disposable air canister. You have a spay can operation using any paint you want. The system is under $10. Reuse the jar and stock up on spray cannisters. Touch up is easy and very little to clean.
    "You can only tie the record for flying low."

  7. #7
    Gilbert Pierce's Avatar
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    Default Re: Winter Projects

    How about a brief description of aluminum brazing.

  8. #8
    Jim's Avatar
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    Default Re: Winter Projects

    Hi Gilbert,

    I'd imagine he's mentioning one of these "solders" currently sold for aluminum use. Many years back there was Lumaweld, a different brand along these lines. I used the stuff back then for repairing the slot in my nose bowl made by a misaligned engine/cowling. A previous repair was resin and glass that wasn't working, the aluminum like product is working very well in that application. Attaching something structural would be a different mind set, probably imprudent.

    To me, brazing doesn't melt the project metal, welding does.

    https://www.muggyweld.com/product/super-alloy-5/

  9. #9
    Stephen's Avatar
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    Default Re: Winter Projects

    Jim, this rod sounds like the same type of rod I use. It is low temp melt, stronger than the base material and flux core. I use my gas welding equipment with the small tip and low pressure. I clean the base material then heat it until the rod flows. The flux seems to be important for the rod to stick. It flows well, and will fill in cracks. I welded .032 aluminum with no problem just be careful not to over heat. I hold the torch well above the base material and add rood until it flows. The thicker square tubing took more heat. It was easy to go over the braze with to torch if It was too lumpy. Cleaning up the flux took a bid of sanding.

    The bond is not the same as a weld, although it is stronger than the base material. I tested it. The weld did not break, the base material did. I only use this on non structural parts.
    Last edited by Stephen; 11-02-2022 at 11:30 PM.
    "You can only tie the record for flying low."

  10. #10

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    Default Re: Winter Projects

    I tried some of the low temp aluminum braze/solder rod that I got at a flea market years ago. Could never get it to flow, maybe never got the base metal clean enough. As long as it is a weldable alloy, I find it just as easy to set the TIG welder up and be done with it. To that end, does that stuff work on the non weldable alloys?


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