welding aluminum/minimal gear

[alloy sailor]

I am a good fitter and fabricator with many different materials. I have done some welding. I want to build solid lifelines for my aluminum sailboat and do some other projects. I need something to tack the parts together and I will hire a pro to finish weld everything. Can this be done with a 110 power supply; maybe a 140 mig with a spool gun I found some good deals on craigslist.

[welder/fitter]

I'd suggest making stanchions/horizontals from stainless with ss base plates insulated from, but through-bolted to aluminum doubler plates, using stainless fasteners.

All of this aside, for tacking purposes, the 140 mig will do it, no problem.

Mike

[alloy sailor]

I like stainless but the boat came with a pile of aluminum pipe for this reason; I could sell it and buy stainless but why would it be better. I see aluminum rails on commercial and recreational fishing boats and looks good and seems strong enough.

[welder/fitter]

That you, Jay?
I've replaced aluminum lifelines & handrails on a few vessels, usually bent badly, but once with tears at the bases, just above the support bracket welds. Always replaced with ss. When I bought one of my boats, the Al dodger frame was a real mess & I've seen others that haven't held up very well. So, mark it all down to personal preference, if you will. Btw, very nice modern-style ph! Brilliant move!
Mike