tunnel repairs

[johndear300]

Wondering if anybody has ever welded aluminum tunnels. I have a Trailfire tunnel with a Bravo suspension and track installed by the previous owner, which required new holes drilled into the tunnel. I'd like to put the original suspension back in and weld the aluminum holes in the tunnel. Don't want to start the project if it is just going to make a mess of the machine. Were the tunnels dipped or coated at the factory to preserve the aluminum? Any ideas? Thanks. Ryan

[ihengineer76]

The '80 Trailfires have a painted tunnel. Otherwise, the tunnel is raw aluminum. It can be welded if you know someone good with a TIG welder. I would cut out a small piece of metal to fill hole first. If you are careful when you smooth our the weld, you should be able to get it to look pretty good.

[chriszildjian17]

I have welded a few. I use the eastwood company tig. It is a long process. I leared from destroyin the fist tunnel i attempted. Small tach each hole. allow to cool for a good 5 min in between or the aluminum will warp. Use little heat, just enough to melt the filler rod. Best to bead blast the area you are welding, then go over with a stainless wire brush. no special coatings. just paint. Find a experienced welder that has done thin aluminum. Maybe get a peice of scrap aluminum the same thickness, drill a hole and have him do a practice before. I destroyed a nice sportfire tunnel on my first attempt. The sides were warped,and bubbled out like was a twisted wreck. hope this help.
chris

[80spitfire]

I'm not a welder personally, but I had my fabrication guy weld a whole ton of holes shut on my Dator tunnel. Granted the holes were extra rivet holes not suspension holes, but they turned out awesome and didn't warp at all. Not sure how much harder the bigger holes would be though.