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  • How to "Weld" Aluminum Without a Welder

    This is great - THANKS. For alternative methods of metal joinery (and those looking for DIY/home tech aluminum joining options) I suggest the following (my experience includes exterior grade aluminum sign fabrication in a hurricane zone):- acrylic adhesives (industrial grades are best - Lord Adhesives and 3M in the USA)- double stick tapes (same)- epoxies (various including above)- mechanical fasteners (nut/bolt, angle iron, etc.). Also, thicker gauge aluminum can be tapped / threaded very nicely, allowing for mechanical screws to be mounted directly into the metal. The right hardware can be attractive.- wire welding (equipment can be rented - ridiculously easy with right equipment)Obviously, make sure you match your product's performance expectations to the fastening method's capac...see more »This is great - THANKS. For alternative methods of metal joinery (and those looking for DIY/home tech aluminum joining options) I suggest the following (my experience includes exterior grade aluminum sign fabrication in a hurricane zone):- acrylic adhesives (industrial grades are best - Lord Adhesives and 3M in the USA)- double stick tapes (same)- epoxies (various including above)- mechanical fasteners (nut/bolt, angle iron, etc.). Also, thicker gauge aluminum can be tapped / threaded very nicely, allowing for mechanical screws to be mounted directly into the metal. The right hardware can be attractive.- wire welding (equipment can be rented - ridiculously easy with right equipment)Obviously, make sure you match your product's performance expectations to the fastening method's capacity. Make sure to read technical sheets, MSDS and fabrication guidelines, in order to make sure you use a product properly and to its fullest potential - most of that can be found online. If you are building something load bearing, that has moving parts, is for exterior use, etc. - you may want to consider consulting an engineer or accessing that knowledge.

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