A question for you welding experts out there.

I was just wondering if any of you have used the Durafix aluminum welding rods before and if so could you tell me if they would work to re-attach the end caps to a set of modified 6th Gen exhaust. TIG welding is obviously superior to brazing but I am still curious to know more about this product since it only requires a propane torch and no flux required. Please see the video below if you are not familiar with this type of product.

DuraFix Aluminium Welding Demonstration Video


Rollin

 

I never used this product, but have used aluminum rods ( the ones you get at any home and garden center) to do similar brazing. Flux is an acid that cleans the metal as you heat it, it doesnt work well with aluminum as it creates pockets and can prevent the metals from mixing. I have always just used a stainless steel brush to clean and a mp-gas torch (note never had luck with blow torches for clean welds). In a pinch i have used a peice of scrap plate to act as a filler rod.

My suggestion is take your exhaust to your local highschool (or colledge) and ask to borrow their tig setup. Some schools offer night classes in "metal work" and you can then learn the skills and use the equipment.

Hopefully a professional welder can offer more.

Zen

 

Forget about those rods and any other brand names of those rods.

The problem is that to use them you must heat the parent material up to the same temperature as what the welding filler rod melts at, and then all the aluminum in the weldment is ready to completely melt at once. The part you are working on and the filler material. It is ok to use on a lawn chair repair but it is VERY TRICKY to use.
Read that twice.

I would rivet the caps on like others I have seen , or go get them TIG welded.

The TIG welding process is easier and better because the TIG torch is about 2800º or more and so you can get in and out quickly and not melt the item you are working on.

The larger the aluminum weldment the more heat it takes because the aluminum is giving heat off almost as fast as you can put it in.

When repairing aluminum body racing cars I have had to use as much as 500 amp machines because the entire body of the car heats up and that large of a surface can give off a lot of heat. Anything attached to the car body can get melted as well. Also aluminum warps even more than stainless.
A special problem.

Never throw water on aluminum right after welding because it will become butter soft.

I am a certified welder and a certified welding inspector with many years of experience with many projects and different types of welding materials and machines.