I have two pieces of aluminum metal. how do i bond them?

**gork** · 08-10-2004, 09:10 PM

Much stronger, no need for any special equipments.

Most pop-rivets are aluminium they easily shear off.

You can buy a pop rivet gun for $3-$5 dollars and a couple big bags of rivets for about a buck. Nuts and bolts are far more expensive. If you need good shear strength, buy better rivets (note that your average hardware store has a poor selection of rivets and they are about 10x more expensive there also) - I have a few 1/4" stainless steel rivets holding close to 1 ton on a shear with no problems. They also cost me 1/2 cent each at the bolt supply!

The project is here if you want to see.

Oh yeah; also JB weld is good stuff but depending on the stress you are putting on it, it's not a great idea. Plus it's even more expensive than rivets!

**Ricky327** · 08-10-2004, 09:26 PM

Nuts and bolts are far more expensive

True

But it depend how many nuts and bolts are needed. He cant be needing 1000s nuts and bolts for a bracket that the overal solution cost far more if rivet was to be used.

A few cent more for a simple nuts and bolts job wont hurt a one off project.

Of course a cheaper solution can be acheived if the bracket was bended/fabricated correctly at the first place

**ShawJohn** · 08-12-2004, 09:24 AM

The easiest way to get a non-structural bond is to use contact adhesive...

- EVO STICK - or similar.

Apply a small amount to each piece and let it dry. Once it feels almost touch dry, press the two pieces together and leave to bond for an hour or so.

This isn't quite as strong as a weld but bear in mind that the Lotus Elise has a glued and riveted aluminium chassis...

HTH

John

**gork** · 08-12-2004, 09:45 AM

Do keep in mind that the adhesives used in manufacturing car chassis and similar materials are quite a bit different than what we are talking about. BMW frames are assembled with adhesives also, and the process is stronger and cheaper than welding (plus it does not weaken the metal), but the adhesive used to do the job is made of some pretty nasty chemicals and has to be heated to something like 500 degC to be usable

**djmickyg** · 08-12-2004, 09:47 AM

TIG it.. i burnt myself with an aluminium welder today.. not fun.

u can also spot weld aluminium ..

jb wold hold i dont think. aluminium is too smooth for it to actually stick.. unless u ruff up the area ur sticking with some real course sand paper

but as most people have said.. the eaisest way without a welder is just riverts.. or little screws and nuts

**Spaghetti** · 08-12-2004, 10:36 AM

Don't forget that car manufacturers have been bonding metal for years - if you look under the boot/bonnet/trunk/hood you will see structural bracing that are only bonded, since welding will distort the panel.

**Enforcer** · 08-12-2004, 01:31 PM

Originally Posted by gork

but the adhesive used to do the job is made of some pretty nasty chemicals and has to be heated to something like 500 degC to be usable

Hmm, I think my carPC could do that sometimes

**brrman** · 08-12-2004, 01:56 PM

http://www.alumiweld.com/

**Redmachine** · 08-12-2004, 10:48 PM

take it to an exhaust shop, 40 bux they'll weld any aluminum /stainless / whatever

**kiltjim** · 08-13-2004, 12:11 AM

Originally Posted by brrman

http://www.alumiweld.com/

I've worked with this stuff, although cool for the fact that it welds aluminum, I've never gotten it to work like its supposed to on thicker metals. Maybe I'm doing it wrong, but I swear its the material.