This is an aluminum project I just finished up. It will be part of a movie prop that will go inside an animatronic lion, to be used in a Bollywood movie. For never having welded an aluminum joint before, I think it went okay. I had more issues drilling the holes than I did with the welding portion. Everything is all 1/8" wall so that worked in my favor too. I was shooting 150-160 amps, 20CFH of argon, 3/32 tungsten in a water-cooled torch with 6 seconds of post-flow. I can see aluminum getting pretty fun with some practice; puddle is so easy to see, like watching a big screen tv.

Just joined and excited to get started. Posting some pics of my latest side quest- a heart for my girlfriend made out of scrap 1x1 tube I had laying around. Was fun to work out all the angles and a bit of a challenge to get both sides symmetrical. I finished tacking it tonight. It will be finish welded, orbital sanded, painted, and powdercoated clear. Will post more pics as it gets closer to done.