Welding Tips and Tricks

The material is 3/32 5051 sheet and alum channel extrusion alloy unknown, rod is 3/32 4043, 3/32 2% Lanthinated, Everlast 250EX with cooler, 114 amps, a/c 165 hz, balance 30% EP, 500 hz pulse, 45% on-time, 50% background.

Here's some more pictures leading up to the previous.

Here's a picture of the rig.

So if you are having problems with heat, back off the foot pedal a little man

One thing that may help as well is to make the one piece taller, with it being that small it will easy become hear saturated..for someone learning using bigger pieces to practices is always easier because you don't have to be as quick and precise with your amperage changes, once you get comfortable than try a joint like that. It also seems,you are running cold. Aluminum welds a lot easier hot and fast so the part doesn't become heat soaked. Cold and slow doesn't work well on aluminum.