Cracked Alpha Z Tower

[Smcqueen]

Please realize spot welding cracked aluminum doesn't achieve anything. It could in fact drive the crack further. You can repair the aluminum. You need to completely grind the crack out and clean the material very well with denatured alcohol prior to welding. Even with all the effort cast aluminum will be difficult to get a good weld because of impurities in the cast material. You do need an experienced welder with aluminum. If mine cracks, I will certainly attempt a repair. It just takes a lot more than welding over the top of a crack.

[IDBoating]

Instead of welding the crack itself, could you weld a small shaped plate of aluminum right over it? Doing so would increase the surface area of the welds involved and it would require only surface prep, rather than grinding out the crack. Just wondering, I'm no welding expert.