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Make sure to thoroughly clean the aluminum area you are repairing with a fine wire brush. Also be sure to wear proper safety gear such as gloves and eye protection when working. Never wear loose clothing or work around flammable substances. Safety is the Key!
Butt Joints - Ends are beveled and brought together. Follow tinning procedure, stroking both surfaces of the joint (with tinned groove) with Alumaloy.
Lap Joints - Parts can be tinned and slid together while rod is still molten, or a generous fillet of rod can be applied to the edges of the lap joint, making sure of tinning by running a stick through the molten area.
Mitered Joints - (in Windows, Doors, Screens & Frames) Material is solidly jigged. A neutral flame is played over the joint area until Alumaloy will melt when drawn across the joint. Make sure of tinning action by running solid end of rod through rod deposit. After tinning, the joint may be built up and finished as desired. These joints are stable in the presence of humidity and have remained in perfect condition after many years of exposure.
Aluminum Repair - (change design of aluminum, match patterns and dies) The section to be worked is cleaned by filing or grinding, then tinned by heating the aluminum to a temperature that will melt the rod when rubbed on. When tinning, the Alumaloy rod should be kept out of the flame, letting the heat from the aluminum melt the rod. Build up with a soft flame. Pre-heat the entire match plate of the die to approximately 600 degrees F facilitates the operation.
Aluminum Welding - (white metal with Alumaloy) Clean plating or scale from surface to be welded. .V. out fracture and set job up solidly. Pre-heat generally with neutral or acetylene flame. Just heat directly until parent metal starts to melt, then dip rod in and out of molten puddle to desired build up.
Stripped Threads - Drill old threads out over size so when new fillet is added all drilling and tapping will be done in Alumaloy. This will make it easier to work with and will increase strength. After drilling, heat base metal from bottom of hole up. Tin rod into wall of hole beginning at bottom and work up. Fill hole, cool, drill and tap as needed.