Hoping someone can help out with this. I haven’t struggled welding anything 1/4” or below, getting a nice shiny stack of dimes, but the job I currently have is whooping my ass. I haven’t tig welded too much thick aluminum and it seems like everything I knew has gone out the window. Project consists ...

Not sure how sesitive anything else is, but when tigging an aluminum cube, Ive found that after letting the cube (or what have you) cool entirely, that jamming a piece of filler rod in the vent hole (assuring the fit is extremely tight- no air leak) and mushrooming the end over, one will be able to ...