he has been kicking my butt until I found this... http://www.faa.gov/regulations_policies/handbooks_manuals/aircraft/amt_airframe_handbook/media/ama_Ch05.pdf
one of the tricks we learned from Tinmantech is he uses 031" 1100 aluminum wire. We have been using .050" 3003 with 3/32 4043 rod the rod is way too thick and cools the puddle too fast. We have been playing with weld angle. We can make the aluminum ripple without blowing holes. If he learns to do this he can do anything and this discipline requires patience and a cool head. This is the penetration of our welds from the other day. What we do is pull out the body hammer and see whose weld stays together.
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