Aren Jenkins Good to know, I'll have to give it a try on a bike! +1 on fitup. Even with filler, the slightest gap can cause a keyhole, and go downhill really fast.

Morning Aren. I have, and it works great and looks awesome. I'm just worried about its long term durability on stuff like a motorcycle exhaust. With the constant heat cycles, vibration, cold water hitting a screaming hot header, etc..... I just feel better having the extra reinforcement of filler material. Just started trying .040" filler, and I like the smaller beads. I need to slow down and/or use a little more heat so the beads flatten out a little more. Never liked the looks of 1/16" as the welds looked huge on thin exhaust, but that was all that's available locally. Finally ordered some .040".

Video no workee!

Nice repair, and some great tips for welding on dirty/contaminated aluminum.

Sam👍

Man that thing was trashed. I chuckled when you said "I don't want this blade coming off". You're the master of understatement, Sam! 😀 Hopefully they notice and appreciate the stark contrast of the quality of the previous repair and yours. Should make for a repeat customer.

Brad GoodmanThanks Brad, appreciate that!

Here's a my coupon for the Aluminum Plate Contest.

Coupon is 5052 .107"x2.25"x8.0"

HTP Invertig 251 set at 130A, 120hz, 70% EN, Soft Squarewave, No Pulse, and current control via TigButton on the torch.

C-K 20 torch, gas lens, #5 cup, 15 cfh Ar, and 3/32" LaYZr tungsten with just a small ball. 3/32" ER5356 filler rod.

There's just a hint of heat discoloration on the backside.

Finally watched this one all the way through. Really good discussion guys! Sure hope you do a Part 2 and touch on tungsten grinds.

Looks like nesting software is likely worth the extra $$ when buying a plasma table. Will file that away for future use, thanks.