Croc said:Got some 3mm stuff left, thinking of putting a bit more solid sheet on the front scoop as well. Still have to add 2 braces to the handle from each top front corner. Welding a bit ordinary, but still getting my head around welding thin aluminium, the heavier stuff is easier.
material under 3 mm is usually done with TIG but MIG works too.
the trick with Ali mig is to clean it well , and use a hot and fast feed rate.
any oxide , dirt or grease on the surface just creates fumes , oxidation or smoke which inhibit fusion.
wire brush before welding is the go.