Welding Aluminum Bicylcle Frames with Mike Zanconato

Рет қаралды 133,711

5 жыл бұрын

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I visited with Mike Zanconato of Zanconato Custom Cycles in Sutton, MA.
After Mike welded a sample aluminum bike weld, we sat down and talked about settings for tig welding aluminum using a miller dynasty 280dx.
The 280 expansion pack, ( which costs around 500 bucks...thanks miller) enables use of independent amplitude settings as well as independent waveforms.
Mike welded 7005 aluminum using 5183 filler metal and he shares the settings used in the talk we had at the end after welding was done.
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Пікірлер: 185

@thzzzt 5 жыл бұрын

Academy Award: Best Cinematography in a Welding Video

@Steve_Just_Steve 5 жыл бұрын

No kidding, absolutely masterful arc shots Jody! Thanks for yet another great vid man.

@tjlovesrachel 4 жыл бұрын

Dr Moriarty your somewhat of a dick.... and ohhh why is mr Hollywood watching blue collar welding videos like a heathen

@zoom0211 Жыл бұрын

I wouldn't be able to learn tig welding without videos like this one. Thank you so much! And I love the beauty of welded aluminum bike frames!

@ricardomontes373 3 жыл бұрын

Top notch cinematography, welding and narration. I always learn from you guys. Thank you for sharing.

@BobbySixguns 5 жыл бұрын

I remember hearing Mike talk about this on the podcast. Helped me get things dialed in during my job change last January. Good video Mike and Jody!

@GUNNER12R 5 жыл бұрын

By far the best video for learning about aluminum settings yet.

@komoto567 4 жыл бұрын

It blows me away just the sheer variance with tig on aluminum... the different tungstens, filters, aluminum alloys, etc etc... like you may be completely dialed in for your production, but be way off if you move to another industry. Goes to show how important it is to stay humble... you can always learn something new!

@Alistair_Spence 5 жыл бұрын

Incredible stuff. Thanks to both of you for making this video.

@kymcopyriot9776 5 жыл бұрын

More amazing, clearly explained stuff I can go and apply right now. Jody and Zanc...both legends.

@ozzstars_cars 5 жыл бұрын

Beautiful weld and great info, thanks!

@JoeyMesa 5 жыл бұрын

Thanks for making this video Jody! Very interesting and informative! Mike does top notch work and he's answered some of my frame building questions.

@KC9RXP 5 жыл бұрын

Just landed my first job welding aluminum truss and these videos have been extremely helpful and let me figure out how to pass a 4g pipe test when I'm 1g material. So thanks!

@billmaguire6216 5 жыл бұрын

I have the Miller 250 Square Wave and for what I do is fine. I was pumping the pedal in 1978, did the job but it would have been nice to have a built in pulse. This was a very interesting take on the current technology in welding machines. I found it fascinating what Mike did with the settings. Very informative, Thank you Jody and Mike

@leebatt7964 3 жыл бұрын

Totally agree on the preflow. It took some time for me to stop being a gas miser but letting go of conserving gas has made my welding much better and vastly more enjoyable. And Ive found it really only means Im going to the gas shop a day or two earlier than before.

@ronmiller682 5 жыл бұрын

Once again great informative video. I wish I could spend time talking and watch you weld.

@quieroverduras 5 жыл бұрын

Thank you for sharing so much information, Mike.

@TheNicko773 5 жыл бұрын

Sweet video..!! So much information, I wish it was an hour long.! Thanks for the upload Jody.

@split150 5 жыл бұрын

Wow, really awesome video and stuffed with nitty gritty knowledge. Those not familiar with inverter based TIG machine and their capabilities might not appreciate it as much, but 7:20-7:40 is simply explained yet so extremely profound.

@petekossaras1830 5 жыл бұрын

Interesting video! Thanks Jody and Mike

@tomherd4179 5 жыл бұрын

That makes sense, sort of "blasting" the cleaning with higher amps but reducing the on time to protect the tungsten. Great information and super quality work!! Unfortunately my tig does not have those features.

@jamesm2872 5 жыл бұрын

Great video! Also thank you mike for sharing some of your tips☺

@mikebest1897 5 жыл бұрын

Great video! I will have to keep that one in the vault for when I get a dynasty.

@garysizemore3729 5 жыл бұрын

Looks like my PK Ripper frame from when I was a kid! Nice work!

@PeterPatterson-vt2cx 5 жыл бұрын

Thats some beautiful welding there mate. Gotta love a good weld.

@elchampeon8772 5 жыл бұрын

you always give the best info on Tig welding. or any welding really.

@erikhafer1415 5 жыл бұрын

That's some of the very best welds I have ever seen, Jesse James could learn from you guys!

@dougankrum3328 5 жыл бұрын

Nice welds...I have and was using since 1981...an Antique….P&H 300 AC/DC Tig/Stick unit, even more crude than the vastly popular (at the time)...Lincoln 300/300.....and yeah, I too learned to use the foot pedal a lot....

@blades2255 5 жыл бұрын

I'm an union ironworker, of course its mostly smaw welding. I enjoy watching these videos you guys are true professionals. Theres something special about a beautiful weld

@15ginger-beardal.77 5 жыл бұрын

I’m a coded pipe welder and have been working in the medical/science engineering scene for over 9 years and welding for nearly 15 years And I can safely say with confidence that the best settings for ranges 1mm aluminium to 10mm gauge is 145- 75 using a 3.2 tungsten with a decent sized AND SHINEY dome on the end.For 6mm+ I use a hot gas. I use a murex 350amp on pedal. Pre flow is 2 seconds and post flow 5. CLEAN material is key no doubt about it. Happy welding folks

@buckhorncortez 5 жыл бұрын

What's your point? You have a "recipe" that works for what you do? Okay...noted...

@15ginger-beardal.77 5 жыл бұрын

Buckhorn Cortez, my point?.. Recipe?.. watch the full video dude, at the end of his video he mentions sharing your own settings and join in the conversation... 🤔

@mt8149 5 жыл бұрын

Thanks for the info. It's very helpful.

@hitchawk4789 5 жыл бұрын

ThisOldTony recommended you, so I watched. Subscribed!

@lehtosenjyri4013 5 жыл бұрын

Wow! Great info! I have similar jobs to do at my workshop. I will immediately try those tricks. I can tune those EN and EP settings in my fronius magicwave. Thanks Jody! Great video again, I have learned a lot from your videos. Greetings from Finland

@johnmacdermid3151 9 ай бұрын

Hi I also have a magicwave 230 as well just wondering if you can share your wave forms, EN & PN settings and what ever settings you dialed in for ally welding would be much appreciated regards Jonymac

@sjbl1962 5 жыл бұрын

Excellent video and great tips, thanks.

@Regalmetalworks 5 жыл бұрын

This is how I weld aluminum 99% of time, except I double my eP compared to eN and run my cleaning at 10% on and 90% off which means it is on eN 90 percent of the time. Can't really do that on a 200 amp machine unless you are welding on thin aluminum. Miller Aerowave, so 360 amps max. I will set 300 amp on eP and 150 on eN to weld 1/4". It works exceptionally well on dirty cast aluminum, like engine blocks, valve covers, & oil pans. I always use a manual foot pulse to help control the flow out as when you are hitting it with that many amps, the heat will change quickly as you move along the part. I like to compare it to a quick hard punch of 300 amps at 10% time to break through the oxidation layer, then 90% of time on eN at 150 amps to lay in your weld.

@GarageTimeAutoResto 5 жыл бұрын

Thanks for sharing your rouge advice. I'm all about non conventional methods if they work👍

@southmaplegarage 5 жыл бұрын

Your channel has giving me the knowledge and confidence to tackle jobs, Im amateur at best but get better every day i light up. I have one request. Tight spot welding. I had to learn real quick how to set up and grind bent tungsten. Some other tricks would be great to hear.

@gordonfreeman9368 5 жыл бұрын

Hi! That is impressive! Love your videos.

@w34356 5 жыл бұрын

Excellent video. Thanks.

@rmschrader36 5 жыл бұрын

That was yet another excellent video! Very interesting about the capabilities of having independent waveforms and amplitudes on each half cycle. For curiosity sake, what are the wall thicknesses that Mike deals with for bicycle building? I have some ally road bikes that are built from very thin tube For the machine set that high, he must have incredible touch with the pedal to drop in welds that nice! Thanks again for the great content!

@sonofthunder. 3 жыл бұрын

im coming to this because of my 💘 of quality welds on MOUNTAIN BIKES

@wtfftw24 5 жыл бұрын

Thanx 4 posting!

@txdocprich_8404 5 жыл бұрын

Sweet video, I can’t find any videos on KZfaq for micro beading lap joints Tplate and padding ten bead overlay test, thanks TWS student

@michaelnelson3985 5 жыл бұрын

Great video!

@weldermike7017 5 жыл бұрын

Awesome loved it! Whats up Mike, weldermike70 here, thanks for the input bud!

@bcbloc02 5 жыл бұрын

Great video, I loved it!

@user-nq1rd8li5t 5 жыл бұрын

Keep doing these VIDS Jody u have helped me a hell of a lot welding Mig and TIG. Any chance u could do a video just for TIG filler rod. Explaining witch 1s to use with different materials etc

@Ryan_1997 5 жыл бұрын

those arc shots👍👍

@MrKidkiller159 5 жыл бұрын

great info guys thanx.

@Bluewater6060 5 жыл бұрын

thanks guys for that information it helps me👍

@JC-un4bg 5 жыл бұрын

I find gas economiser help with arc starts because you losse the surge in gas at the beginning creating turbulence . Plus it does save gas when tacking

@rvalcourtpersonaca 5 жыл бұрын

Good video guys! Just just started practicing on aluminum pipe 1 1/4” dia 3/16” wall, I wish my welds looked like Mike’s but I need a lot of practice. ... lots! This foot pulse method sounds good gonna try it right now. Would you recommend any kind of prep like, bevel size of landing or gap?

@JP-gc5in 5 жыл бұрын

Great video, great info

@stcfabworx1687 5 жыл бұрын

I have some of those settings on the aero wave I believe. Not as extreme but they are there.

@garyrhodes7089 5 жыл бұрын

Good video would these frames be heat treated after welding ?

@jcl1201 5 жыл бұрын

Thanks for the info my mason buddy

@MOUNTAINEAGLES 5 жыл бұрын

The best KZfaq academy. *MOUNTAIN EAGLE*

@user-xo6ge3fv3d 5 жыл бұрын

Good work sir

@itonjoans354 5 жыл бұрын

you should make a video showing how to do the pulse function with the foot pedal.

@tjs_welding_and_fabrication 5 жыл бұрын

Great info great vid.

@wadepatton2433 5 жыл бұрын

ZANK! Hey man. Jody--this is sort of joinery I've got to have a good machine for someday. But now I'm off on another tangent with wood and pre-welding-era(historically correct) metalworking only.

@gbtalk5550 5 жыл бұрын

Hi Jode, another great video. Just got new tig welder AC/DC similar to the Everlast you have previewed. I am looking forward to learning how to weld Aluminium, is their a filer rod which I could be use for many type of material. and silica bronze what type would you use for building up a worn shaft then machined and general jobs? I am a hobbyist here in the UK

@stevenfairclough5745 4 жыл бұрын

A quick question. Can you weld over a small crack in a lower wheel stay on the crank side, and it still be strong enough to ride?

@rkvktmen 5 жыл бұрын

Do you have any advice about when (or if) you need to heat-treat aluminum after welding? I thought that was standard practice for aluminum bike frames?

@brentdavis4867 2 жыл бұрын

it highly depneds on the series of aluminum used

@lucianosantos-soldaprecisao 5 жыл бұрын

Muito bom gostei do vídeo. Brasil

@alanhatch7121 5 жыл бұрын

Learnt loads cheers 👍

@exvils 5 жыл бұрын

I am using topwell alutig-200p, can set different waves, balance and amperage on en/ep. Bought it for 600€ brand new. I am not a welder but i wanted to build racecar (and 200A seemed enough for me) -welding thin steel/SS/thin aluminium. Tig made welding fun&cheap for me, 12L bottle of 4.8Argon cost 10€, filler few € to none

@sylvestresanchez4848 5 жыл бұрын

Thank you

@mirage2598 5 жыл бұрын

hey jody you you should make a video about welding aluminum that has that iodine finish

@Regal2800 5 жыл бұрын

how about penetration with more EP over EN? Are you getting the same or less penetration? Any other benefits to higher EP other than saving the tungsten? It probably wets out at the toes better with higher EP. I have been struggling with the independent EP vs. EN for a while now.

@ibanezjorge771 5 жыл бұрын

Hi jodi which ac/dc welding machine would you recommend to buy I like to start tig welding aluminium

@nanogonzalezdj3388 4 жыл бұрын

Thank you for this info. It is just aesthetics, but is there any way of smooth the weldings in an aluminum bike frame?

@DCweldingAndArt 3 жыл бұрын

What do you mean exactly by smooth? Like to lay more flat? I have found that a lower frequency, probably closer to 80 or 90 hz, and maybe adding a small bevel on the joint(will help sink the filler in), and soft square wave if you have it. That ought to help, and soft square I believe requires a little more cleaning(maybe 65-70% EN balance) good luck!

@shootingcenter1776 5 жыл бұрын

I have a question about the Dynasty 350, can you independently adjust or choose the wave form for EN and EP on the 350? I know Zank has the 280 with the expansion. I can independently adjust the EN and EP but I'm trying to independently adjust the wave form for each EN and EP and cannot find the setting on my welder.

@OmarUnikel 4 жыл бұрын

Hello friend, I greet you from Mexico City. Congratulations, you do an excellent job. Questions: What type of supply rod are you using? and I guess that aluminum of the bicycle frame is 7000 series? And finally, what machine are you using? Greetings.

@mortenhansen3455 Жыл бұрын

I have a question; Are alu welds so thick that it's possible to smooth them out on a bicycle frame? Or should a buy metal spartle and smooth them out that way? Greetings

@beachboardfan9544 5 жыл бұрын

Thought it was bad to pull the filler out of the shielding gas while running the bead, or is that not a thing with Al?

@Xyz-ij6rh 2 жыл бұрын

Im would like to know at what Frequenzes hes working and if it has an impact on what he experianced

@raulmunguiasalazar6189 5 жыл бұрын

Pregunta!! Que aporte de soldadura es 4043??? O es otra

@Dave_Menz_p4p_number_1 5 жыл бұрын

Do you have hair plugs in the front? Just curious

@caseyledford3662 5 жыл бұрын

Jody- I am looking to purchase some tig rod for my home shop. My welding school supplies some Harris brand but also some unknown brands. I know they are all adequate for practice but I was wondering which brands are the most sound for making critical welds. I have read about manufacturers posting specs and certain verifications on forums and such but I dont speak that lingo. I figured you might be able to explain. Thanks.

@turbocobra 5 жыл бұрын

Excellent discussion fellas. I have been welding some 1/4" 5052 lately (4043 filler). Tried freq of 60-120, AC balance from as low as 65 up to 80. Was not able to get a clean puddle. Tried a scrap piece of 6061, welded super clean. Anyone have thoughts ? The 5052 does seem to have a very heavy mill finish / oxide layer on it.

@weldingjunkie 5 жыл бұрын

Ramsey Customs - turbocobra Gary you using the invertig? You can set your AC amplitude EN down some try to set it at 60% and adjust the amps to compensate. Your EP will stay at 100%. That Invertig should be able to do that job flawless.

@michaelwahl9281 5 жыл бұрын

You would be better off using 5356 filler on the 5052 aluminum. More of a marine grade.

@weldingjunkie 5 жыл бұрын

Michael Wahl 5052 high strength allow which has 2.5% of magenesium in it which is really non heat treatable less expensive than 6061, and 5356 will help with cracking as well, so unless it’s marine like you said. 5554 is a better rod to use but hard to find. You cannot weld 5052 autogenously either you need filler and 4043 will work just fine as well. But 5356 is fine too both will work no problem. I guess 5052 people just assume marine because it’s so popular but I don’t know what he’s using it for. He never replied.

@geonerd 5 жыл бұрын

Cool. Thanks! :)

@cyosh345 5 жыл бұрын

Im a beginner. How do I keep the tungsten from balling up or is that normal for working with aluminum?

@SvcGlobal 5 жыл бұрын

Nice!

@pulse5217 5 жыл бұрын

How do you or Mike feel about the sort of "DRM" Miller has where you HAVE to buy the expansion card, to have features the machine can already do?

@tjlovesrachel 4 жыл бұрын

We need weld hackers to jail break it or write the software for half

@anakinskypooper5581 3 жыл бұрын

Thank u 🙏

@greedycat4026 Жыл бұрын

what aluminum should u fix with E5 premium frames?

@goose2goose2 5 жыл бұрын

Hi Jody !! Get yourself a Bode Mike...we got one and the echo in shops vanishes !! Big Improvement. Do yourself the favor..big gain in audio quality.

@Steve_Just_Steve 5 жыл бұрын

Why did you stop posting? your Wind Sculptures are awesome! Are you still making?

@TheKajunkat 5 жыл бұрын

yes it is a rode video microphone. It does really well with a dead cat (yes that is the brand name) furry wind cover. Really cuts down on wind noise and echo. Get both and it will be the best ~$150 you will spend on video quality.

@wadepatton2433 5 жыл бұрын

Go back to the very early years of Jody's vids to see just how much better his audio is now. It used to be all crunched up on the top end. WAY better now, even with echoes in the nekkid shop.

@goose2goose2 5 жыл бұрын

Hi SJS.. I'm ( very ) alive and well and busily making wind sculptures ( about two new creations a week ). ( when I'm not out shopping for sexy new outfits !! hehe The mike name is RODE..my bad..so sorry > They work great !! Please go to my you tube site....here: kzfaq.info/love/2uuzLGOwTquXXmPK_fyuNQ I hope you like what you see !! Savanna

@goose2goose2 5 жыл бұрын

Yes Bill..Rode Video Mike Go...it was not expensive and took the echos out of our shop videos and outside, the sound was much cleaner and louder. I use a Canon SX50 camera and it's a good combo. Please have a look at my you-tube page Please !! kzfaq.info/love/2uuzLGOwTquXXmPK_fyuNQ Savanna

@nandagirirajesh3638 3 жыл бұрын

sir what is the base material(6061?) and filler rod(ER5556?)

@bornlevi 5 жыл бұрын

Great vid thanks. Does Mike Z have social media accounts ?

@mordantly 5 жыл бұрын

All Dynasty DX share the same expansion up to the 380 or 400. Then tit's included out of the box. My 210 DX sure would be sweet with it. But I don't pay my mortgage welding aluminum.

@MG-og4zp 5 жыл бұрын

Can't find small furik cups on ur site or even online..i was going to order a #8 and 10 is there a starter kit with these? Awesome video!!

@weldingtipsandtricks 5 жыл бұрын

weldmongerstore.com/collections/frontpage/products/furick-8-pro-cup-4-pack-br-for-9-20-torches

@MG-og4zp 5 жыл бұрын

@@weldingtipsandtricks thanks! I guess i need the adaptor also..maybe a starter kit with those size cups!? U rock!!

@051658 3 жыл бұрын

I used to ride a recumbent trike, and a car hit me, so the frame fractured and eventually broke a part , I’ve seen some videos in which I think it can be weld, the problem is where I’m nobody knows how to do it, so if I could send you some pics for you to see it, and let me know whether it can be fix or not. I thank you before hand and hope to hear from you Carlos

@andreydavidenko3212 2 жыл бұрын

Please tell , is it real video on 2minutes no slower than original? Thanks for information.

@curtbelshe 5 жыл бұрын

What gas mix is he using, how much helium?

@billybobscat6233 5 жыл бұрын

Anyone know what aluminum series a Cannondale sm500 is? Im restoring one and I can't seem to find the info I need on this so I know if it can be tig welded or not without weakening the frame. .

@circuloespacial6217 5 жыл бұрын

hoo my god is a good job bos

@mrgreenswelding2853 5 жыл бұрын

What grade aluminium does he use?

@jacobjames1171 4 жыл бұрын

Some people will show you the door if you go in and try to pedal pulse their welding test. I do like it and do use it from time to time.

@sgrasmick82 Жыл бұрын

What filler rod is used?

@skinnyg214 5 жыл бұрын

Since I started welding I've wanted to build my own bike.

@C2welder 5 жыл бұрын

Anthony Rector Me to I wish there was a kit available.

@deathsicon 5 жыл бұрын

I got into welding to eventually build a motorcycle, now I'm working on getting to a point where I can do repairs on my friends mountain bikes

@westwater73 5 жыл бұрын

I've always wanted to build a self contained independent shark cage, with 5x200mm 316l box section able to be charged with diving gasses,adjustable buoyancy the hole works.. The only reason I probably haven't is that I weld all day at work. About 12yrs ago I wanted to build a luxury wide beam live aboard canal boat, rented a yard next to a canal next to a steel supplier, and that was as far as I got with that!!!!!

@atVVV1 5 жыл бұрын

Ive been designing a titanium time travel machine.....with pedals....in my head....

@wadepatton2433 5 жыл бұрын

I've built my own bikes (guided and encouraged by the bicycle frame building community), but both were brazed (lugged roadie and fillet brazed MTB). If you guys want serious light/performance bike you have to source butted tubing from the bike tubing suppliers. If you want utility/cargo/just trying it out type of bike (practice getting your geometries/function/alignments correct) then about anything will work so long as it will sustain your loads. Straight gauge 4130 is as simpleton as I'd try (it gets a lot more complicated and expensive in the butted and alloy variations. My steel came from Henry James/TrueTemper and Columbus (Spirit for Lugs/PeggoRichie) I got direct from Richie. I don't know who is left in tubing/lugs suppliers. I don't work aluminum for bikes so cannot advise you there except that the entire frame must be normalized after welding and alignment processes are complete. And that Titanium is what I really want to play with next. Rody Walter works with (bicycle) Ti quite a bit and has a few videos up. Bikes are rather simple, BUT there's a bit more to it that meets the eye (of the non-engineering sort, or performance oriented type). The info is out there. Best of luck. Also you might find it interesting that the standard frame geometries of production bikes are limited and do NOT fit everyone. I'm an example. My bikes ride better than anything I can buy without hiring custom framework, because they put my hips in the proper place relative to my feet and hands allowing best articulation of the legs for power and efficiency. It's a journey learning all these things. Lot of great builders out there have it sorted out already-if you just want a great bike for your purposes. Mike is one of 'em.

@jojomama4787 5 жыл бұрын

Was welding probably thirty years before they came out with square wave,I finally got a square wave so I could welding anodized aluminum cleaner.Now way back when I was welding "Champion" motorcycle frames and making aluminum swingarms and that was just plain old A/C machines,we sent out the swingarms to get heat treated and anodized,THAT'S when I welded up my first aluminum bike frame...maybe I should have stuck with that!