skill defecit makes me waste time (to save feul!)

[Jason Maki]

I am sitting here waiting for the UPS (prounounced OOOPS!sorry we broke it!) truck to bring the ALI eggbars I need, and contemplating my need for a boxy wedged 14 1/4 inch ALi straightbar on friday , I am frustrated. I have been able to avoid my lack of skill in forge welding Aluminium for 11 years, and today it has bit me on the butt. The rest of my week is going ot be jabberwockied because I have to wait for some eggbars or drive 140 extra miles round trip to come home and get them after the OOPS! truck runs.
Will someone smarter than me build a barshoe (does not matter egg or straight) out of ALi...taking detailed pictures of how to set up the scarf , what Al rod to use, where and how to place the rod, how to judge when to pull the shoe, and how to press the scarves together. Maybe a few pointers on forging the bar after it is welded? I would be forever in your debt. And my time and pocket book would be eternally grateful as I would not be wasting a morning waiting for something I should be able to build, and I would not have to pay $25+ a pair for shoes that could sit and oxidize for years.
Thanks,
Jason

[Joey Aczon]

Just make a barshoe with the ends rounded and butted up against each other, then get some Al welding rod and use the oxy / ac. Bingo Bango! :D

[Jason Maki]

I'll try that, but would really like to be able to forge weld it.
Thansk,
Jason

[brian robertson]

With Al it's not really forge "welding" it's forge sodering. Like sweating copper pipe.

You can make traditional scarfs or b u t t joint.

Cleanliness is next to godliness with Al.

Mechanically clean with stainless wire brush (that has only been used on Al); chemically clean with flux; place cut piece of Al rod 2x width of stock bent in half on top of seam (do not touch with fingers)

I use a 6"x6"x1/4" piece of stainless to rest the Al shoe on; cuts down on the # of oops. slide into forge just to the side of burner (hot spot) and WATCH the Al rod will ball up first, then, if everything is clean, it will shoot into the joint. Very carefully remove the plate from forge; do not jiggle or drop it, the shoe is near molten and only the oxide on the outside is holding it together, let cool the file/grind to final shape.

[Jason Maki]

thanks! i'll give it a go