Cutting/grinding aluminum.

[Dave9]

What about sanding it down flush with the cross member? I'm just going to cut them off completely and go with adjustable bolster mounts, so i can fine tune it to my liking. Is a flap disc the best? I do have an air powered sanding disc like what you would use for body work

I'd just cut it flush then grind down, with what you need to weld on and go from there.

I doubt the original rail was hardened considering aluminum. At the same time I am not a pro aluminum welder so best advice is consult someone local who is.

 

[The motor guy]

Really, what is your plan for rebuilding this? Have you ever welded aluminum? Do you have the welder and consumables? Do you know a guy? Did he give you a price?

If you have to ask us how to cut the thing off, you're waaaaaay over your head.

Mig welder

 

[Pablo]

I'd just cut it flush then grind down, with what you need to weld on and go from there.

I doubt the original rail was hardened considering aluminum. At the same time I am not a pro aluminum welder so best advice is consult someone local who is.

Why wouldn't it have been? Most all extruded 6061, etc Al tubing at least is quench and age hardened. But, I doubt it was altered after welding, typical. So more welding will create even softer areas. I dunno, this would bug me.

 

[D60]

Mig welder

You'll need straight argon and ideally a spool gun (or ReadyWelder).

Practice first on scrap and get everything really clean with dedicated grinding wheel, sanding disc and wire brush. Label as such and don't use on ferrous.

Post up results!

 

[spasm3]

Why wouldn't it have been? Most all extruded 6061, etc Al tubing at least is quench and age hardened. But, I doubt it was altered after welding, typical. So more welding will create even softer areas. I dunno, this would bug me.

I'd go with your 4x4 or 4x6 idea and skip all the welding.

 

[The motor guy]

I'd go with your 4x4 or 4x6 idea and skip all the welding.

I'm not going to weld anything. I changed my mind

 

[The motor guy]

I'm not going to weld anything. I changed my mind

but I am going to cut off what is shown. Just not weld anything back

 

[The motor guy]

This I would block it up as well. 4x4? 4x6?

Welding again at the same area, it's probably already gone annealed (dead soft) - no longer Al in the tempered T4, or T6 condition.

The blocks of wood eat away at the aluminum. Noticed heavy pitting on one of the main cross members. Probably whatever chemical they use to treat the wood reacts with the aluminum. I used an air powered sawzall to cut one off. Yes, I finally got around to this project. Then I used my airnpowered auto body sander to grind it down. Its a slow process, but its working lol

 

[Chris142]

Sawzall? A finer blade will load up with aluminum fast so a coarser blade.

 

[The motor guy]

Sawzall? A finer blade will load up with aluminum fast so a coarser blade.

Nothing loaded up. The teeth were clean. Still are clean.

 

[Pablo]

The blocks of wood eat away at the aluminum. Noticed heavy pitting on one of the main cross members. Probably whatever chemical they use to treat the wood reacts with the aluminum. I used an air powered sawzall to cut one off. Yes, I finally got around to this project. Then I used my airnpowered auto body sander to grind it down. Its a slow process, but its working lol

So are you not going with wood at all? Maybe something untreated like a mild hard wood or dougiefir?

 

[The motor guy]

So are you not going with wood at all? Maybe something untreated like a mild hard wood or dougiefir?

No, cutting off the welded on posts and installing adjustable bolt on bolster brackets

 

[Pablo]

No, cutting off the welded on posts and installing adjustable bolt on bolster brackets

Cool. I needed catching up. Thanks

 

[The motor guy]

They dont necessarily need to be totally cut off. Just cut a hole for the ubolts to go through them because I'll be there all day trying to grind them flush with the cross members