[metaldreams]

I am trying to butt joint some 2" aluminum square tubing which is 1/8th inch diameter. when I weld it together i am not getting complete penetration. Should I expect to be able to get a full penetration weld on this thick of aluminum? I don't really need a structurally perfectly strong joint but would love to know what the gold standard for this type of joint should be. Should I bevel the edge of aluminum to improve penetration? How would a professional approach this joint?

[Sandow]

Are you mating the plates up flush or leaving a gap between them?

-Sandow

[DLewis0289]

Don't bevel, gap them a little bit.....a LITTLE bit (less than a dime thickness). Tack on the corners and run tack to tack. Don't really need gap at all, CJP not really required as you stated but easier to see the line.

[metaldreams]

I was not leaving a gap so I will try that. Thank for the replies

[DLewis0289]

Unless you are used to doing open root...... if your filler wire falls through the gap, it's to big.