How much do you know about welding? To do a proper job you can't just slap some weld on the surface. He took it apart to bevel the mating surfaces, creating a crevice for lack of a better word. Then he put it back together and filled the crevice with weld. The first pass of weld is called the root pass and is the most important one. After applying each pass the flux needs to be chipped or ground out so there are no imperfections or voids in the subsequent passes. after the last pass I would imagine he ground and polished the surface.
Originally Posted by SonnyThomas
There is a problem with welding, though. I don't kow about aluminum but welding steel changes the molecular structure of the base metal. It weakens it. The weld, if done right, is actually stronger than the base metal.
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