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.

Yes, any sort of small tank builds are of interest to me. And maybe touch on filler rod selection tailored to the tanks use. I bought my first TIG welder specifically so I could weld aluminum, and build an oil tank for one of my motorcycles. Tank is 5052 and I used 5356 filler. Only to find out later that 5356 can be susceptible to cracking if exposed to 150F+ temps. Well this tank will never be below 150F when in use! So it will be a do over with 4943. Didn't do my homework there!

The owner is going to want a new boat, now that he knows what great aluminum welding looks like! Nice job.👍

Great idea for punches, pencils, etc....Will add to the "to do" list! A magnet glued in the bottom might be handy so it stays put. Mine damn sure won't look that good, but I'll try. :)

Sounds like fun! Just getting used to a new HTP Invertig 251, and this will be a great way to get in some practice time with it. 

Brad GoodmanAppreciate that info Brad, thanks!