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for a more detailed article on Tig welding thin aluminum go here goo.gl/QQZyRc This weeks video is on tig welding thin aluminum in the 1mm or .040" thickness range. You can go pretty thin with 3/32" if you sharpen it but in order to get the best results, Tig welding thin aluminum requires use of smaller electrodes and filler wire.
For this video, I used 2% lanthanated 1/16" electrodes (1.6mm) and same size filler wire. I would have preferred a smaller filler wire but I just didnt have any on hand.