Thread: Tig welding thin sheet aluminum to thicker plate

Trying to fix an aluminum dirt bike muffler that has a big hole in the side. The original plan was to take some aluminum sheet metal, cut to size, bend/curve it to shape, and weld a patch over it. Unfortunately my tig skills aren't quite up to it so it seems.

I can get a good puddle and lay a bead on the muffler at around 55amps, but anything above 40 or so just burns straight thru the thin sheet metal.

Any tips on making this work? I tried concentrating the heat onto the muffler surface, but when I try to flick the torch over the sheet metal it just burns right thru.

Tig welding thin aluminum
There is a lot of good tips there. Hope that helps

Try using some of the settings used to TIG aluminum cans together...that stuff is really thin! Here's a good video for reference Welding Tips and Tricks.com