CUTTING 360 WHEELS FOR A 328

Are you making this stuff up as you go? Seriously? About the only thing made from 1100 series aluminum is electric wire, it isn't strong enough for much else. There are ohter alloys such as 5056-T0 that matches it's ductilitly but has a yield strength of 22 ksi vs only 5 ksi for 1100-T0. ER4043 is the only aluminum welding rod in stock at most welding or welding supply shops because it works pretty good on just about everything. ER5356 is readily available, but almost alway needs to be ordered....because it cracks if you don't pre-heat well or try it on cast material, it is a bit strongth though. I spec this stuff everyday, it what I do for a living.....

 

Yup. I'm just winging it.

What I'm not making up is that I use 1100 welding rod to join 3003 sheetmetal. It welds well and matches the color, both for polishing and for anodizing. Should I be using something else?

 

Honestly, I don’t ever deal with 1100 or 3000 series alloys because they are not strong enough for the type of things I deal with, but a quick check of my references all say that you are correct:
One says:
Welding is readily accomplished by means of conventional welding methods. Filler rod is generally AL 1100 alloy. When welding AL 3003 to other aluminum alloys, such as 5052, 6061 or 6062 the filler rod should be AL 4043.

The second book says 1100 or 4043 for max elongation, 5356 for max strength, but is talking specifically about tig welding.

A third reference says on 3003 use 1100 for ductility or color match after anodize and 4043 for strength or crack resistance.

On a side note that lambo fender was probably a 5000 series, forms well and less dent prone than a 3000 series, but gas welding with 1100 rod will make it crack every time. If I don’t know, I try tig with 4043 first, then 5356, then order a new part that isn’t broken.

Getting back to wheels though, if it was a cast American racing wheel or some such junk going on a light car like a Honda, I’d never think twice about welding it. If it was going on a 6000 lb SUV, I would think twice, but I’d still probably do it.

But Speedline or other premium wheels are a different story. They are made from premium materials, then process to get the most out of them (which means work and heat treating), then made as light as possible (which mean low safety factor). I don’t think I would mess with cutting and welding those, especially if it was just to avoid buying new springs

 

First off, its Krowbar, and secondly yes I have flown, and worked on aircraft, but admittedly general aviation aircraft, not commercial. I also know nothing I ever flew or worked on had anything in or on the engine welded on, except the exhaust. Also, I notice you are in France, and NOT the US, and I assume our regualtions differ. I will however state that up until just a couple years ago, as I have been away from planes for a while, welding was not an acceptable repair for many items on an airplane. Things that I know could not be welded, included all crankshafts, camshafts, engine cases, propellors, landing gear components, etc. The only possibilities were if the manufacture allowed it and had proven to the FAA that it was an acceptable repair on that particular part and only under simular circumstances. For example, if it was a common condition that a part would break in a particular location, and the original manufacture found a suitable repair that involved welding and proved it to the FAA, the FAA could allow that repair.

Steel tube can generaly be repaired, by surrounding the tube with a larger tube that extends well beyond the failure, and fillet welds. But in general, no castings could be welded, and certainly nothing structural.

Having said all of this, I am also quoting other sources, and can admit I do not know a lot about metals and welding from a deep physical standpoint. But I would also be suspect of a wheel that had a large section removed and had been welded on, just in general terms. The liability today is just to great. I just don't know if I would want them on my car, and before I would sell the car, I would destroy the wheels before selling them to anyone else. Everyone is just too sue happy today. In other words, I wouldnt want to send my daughter down the road on them.

 

It's done all the time. Sanford Kosman, of Kosman Racing Specialities in Healdsburg, California (jusr outside of Santa Rosa), regularly widens 17" motorcycle wheels, and they are used in drag racers, etc. I'm sure that if you give him a call, he can do exactly what you need, and is probably set up to do it right. Martin, his shop forman, is probably one of the best welders in the USA.

Art