The Natural Angle: Welding Aluminum

November 2001

Welding Aluminum

Welding aluminum in the gas forge is technically a brazing process. The series of photos illustrates the steps in building an aluminum barshoe from a Kerckhaert long heel aluminum shoe.

Aluminum doesn¹t require a lot of heat to forge. Begin by placing your shoe in the forge and heating to a forging temperature. One method to check the temperature is to use the end of your hammer handle. If you wipe it across the shoe and it doesn¹t leave a mark then the shoe is probably too cool to forge. When it leaves a burn mark it is ready to forge. You can use an 800 degree temp stick to help determine the proper heat level.

Start by turning the heels and scarfing the ends. Bring the heels of the shoe together so the ends overlap. Make sure the lap is as tight as possible. You are now ready for the "welding" process. The Welco brand, 1/8" flux core aluminum brazing rod (melting temperature -1000 degrees) works well for this application.



Place a piece of the rod on the lap area of the shoe. Then place the shoe in the forge. Do not place the lap area directly under the burner and be sure there is heat circulating under the shoe. You want the aluminum to heat evenly before the rod melts. Just before the small piece of rod begins to melt, stick the end of the longer rod in the forge to get it heated. As the piece melts, your longer rod can be used to "wipe" the area and it will also begin to melt. Pull the shoe from the forge and continue to filling the lap area, on both sides and the edges until the gap is completely filled.



Place the shoe on your anvil but do not strike it immediately. You need to let the shoe cool before finishing the forging of the area. You can check it with your hammer handle. When it leaves no mark you can then forge the area to the desired shape and finish with your wire brush

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