Welding thin aluminum air condintioning tubing? - Defender Source
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Old April 4th, 2009, 10:02 AM
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Chris Davis
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Welding thin aluminum air condintioning tubing?

On my Disco, there was a wire harness rubbing against my low-pressure side aluminum air conditioning tubing and made a pin hole leak. This is basically right behind the engine and this tube is going to be hell to remove so I was thinking of fixing it in place. Does anyone have any advice on fixing this? Can I solder/braze it? I don't have a tig welder (well I have a Ready Welder that could be a spool gun, but this is a tiny hole in a hard to reach area).

Ideally, if there was some sort of a cold fusion weld or a JB weld that could be used, that would be number one. Number two would be probably using a pencil torch and some aluminum rod if something like that would work.

Any ideas from those with experience on something like this?

Thanks!
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  #2  
Old April 4th, 2009, 10:30 AM
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Quote:
Originally Posted by Davis
On my Disco, there was a wire harness rubbing against my low-pressure side aluminum air conditioning tubing and made a pin hole leak. This is basically right behind the engine and this tube is going to be hell to remove so I was thinking of fixing it in place. Does anyone have any advice on fixing this? Can I solder/braze it? I don't have a tig welder (well I have a Ready Welder that could be a spool gun, but this is a tiny hole in a hard to reach area).

Ideally, if there was some sort of a cold fusion weld or a JB weld that could be used, that would be number one. Number two would be probably using a pencil torch and some aluminum rod if something like that would work.

Any ideas from those with experience on something like this?

Thanks!
Hey,

Check out a a product called Devcon Aluminum Putty. It's expensive, about $40, but it will get the job done for you without issue. I may even have some I can send you, but you have to send it back to me! It's a two part kinda like bondo.
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Old April 4th, 2009, 07:41 PM
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Jim Cheney
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You can also drop by a Thermoking and see if they'll help you out.
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  #4  
Old April 8th, 2009, 09:53 AM
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Chris Davis
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Buck, that would be AWESOME! I will PM you.
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Old January 9th, 2010, 01:29 PM
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Just as a followup, the devcon putty idea worked. I cleaned and lightly sanded the aircon tube, applied the putty and let dry. I have used the air conditioning for almost a year. Very cool stuff.
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Old January 9th, 2010, 06:38 PM
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Don Bunnell
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Just to add some more about the Devcon Putty - I bought some to fill in a bunch of holes in my tub from a rear ST seat I took out. Overall it worked great and if I prepped the bigger holes better you wouldn't even noticed that tub was drilled. Expensive but its probably easier and cheaper than finding a good aluminum welder.
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