Tig Welding Aluminum Pie Cut Tubing 

A little bit of a fixturing tip for all of you. I do a lot of custom pie cut exhaust work. I use hose clamps (gear clamps) to build my assembly and hold my pies together. For larger diameters I've drilled holes in my clamps for access to make tack welds. It works great and holds the orientation of my assembly really well.

Don't kid yourself Jody, this here is the "ONLY" place to be for welding videos on RU-vid! I just enjoy watching a master (or in this case, a couple of masters) at work. Pure welding poetry!

Hi Jody, there might be other welding channel choices out there but they don't even come close to your channel. You are the gold standard when it comes to welding with integrity and precision and detailed information. The video quality is the best, the voice over narration is the best. The subject matter is great. Thank you so much!

When I was growing up, young lad, there was the opportunity to take a shop class in school. I skipped that opportunity and 30 years later wish I had not. What you offer us in these videos is what we may have missed, or education not offered in today's schools. Anyone hear of a shop class these days? Not here, not near DC. So, thanks for sharing what you do.

We watch your videos in my welding classes over at the college. You're an incredible welder and your videos have helped me immensely!

I haven't seen any other videos that come anywhere near close to the quality and knowledge you give Jody and with a good sense of humour :) Many thanks, learned lot from you the last couple of years.

I go back and watch your videos from time to time. Learn something new each time. Im Getting better tigging all the time. Your torch manipulation just works. Trying to imulate your style. I like it. Thanks Jody

This really was an awesome collaboration guys. Amazing editing and transitions Jody. Just joined the podcast patrion, forever greatful for how you have helped me step it up. Be blessed!

This guy is ridiculously good at what he does.

Hi Jody, Thank you for the video's you make it very understandable. I've been welding for 37 years and you are never to old to learn new tip and tricks. Thank you Joey Sams

Hey Jody, I know this is an older video of yours, (I'm just going with the flow that RU-vid gives me on autoplay) I've noticed at the end of the last 8 of your videos I've watched that you are always sure to mention that you know how many other channels are out there and how appreciative you are that someone chose to watch your video(s). In addition to how informative your videos are you express general gratitude towards your viewers .That's pretty damn awesome in my opinion. Been subscribed to your channel for close to a year now, never a bad video! Keep up the good work bud. I can't wait to be able to afford a decent little TIG machine and get my feet wet. But for now I just live vicariously through your videos.

Thanks for the advice on machine settings, angle orientation relative to weld placement and always the heat considerations of beads so close to one another. I am getting back into TIG welding after a 40 year hiatus. Happy New Year and I look forward to many more of your great videos

That's a pretty piece of art and Roy's welding just makes it even prettier. Very nice!

In my opinion you make the best most informative videos on welding that are available. I took welding at a 2 year college and finished but I'm rusty cuz I have not welded much in 6 years. Your videos have helped me remember a lot that I forgot. Thanks for what you do in helping us guys.

great work im supprised the tape was enough to hold its shape in the 1st place,

Jody I've been welding self taught for the last 14 years I can weld aluminum but after watching your videos I feel that I've learned alot I'm not good with all the technical aspects of welding specially when it comes to aluminum but your videos help alot thank you

As usual, EXCELLENT video! Also, I got my tig finger bundle last week, and it changed my life. Love it! Keep up the good work!

Hey man. Thanks so much for taking the time and effort to make these videos. There are a lot of welder channels out there but i always learn the most from yours! Keep it up !! Much love and appreciation from the netherlands

spent sometime in your class room this eve Thank you!! Happy New Year Brother!! ..BTW loving the M 211!

Thank you for doing this video, I actually requested you do a video about welding aluminum piping for automotive use several months ago. So again thank you for taking your time to do this. I will definitely try the tips & tricks you've talked about in this video.

This is the kind of channel you learn from. Love your videos and because of you and your very well made videos, my instructors dubbed me a welding prodigy. Thanks to you and your videos. I greatly appreciate and am honoured to have found your channel. ~combination welding student

Perfect timing. I'm just about to fab up my first intake. Thanks for another amazing video, Jody.

Hey Jody, I'm a newbie, but your videos outdo everyone by far. Thanks and I'm a believer!

So happy to see this video! Once my header is done i'll be working on the intake parts pretty much the same way. It's really helpful for me to be able to get an idea at least of what the start settings should be and go from there! And a big shout out to the Tig finger! I use it all the time and love it!

Great to see in detail how to handle the tack welds, including the technique with torch and the welder settings. Seeing how nicely your welds turn out is a great target for knowing what is possible!

Another great video, Roy is a welding god!

Your explanations are excellent and you are a natural teacher. I've done lots of mig off and on over the years and plan on doing more in the very near future, but I really want to try tig. Thank you so much for these videos.

dang Jody, I missed you bro! another great video. I've seen this done with stainless for exhaust set-ups and that rainbow effect is killer! happy new year to you.

Thanks for posting such informative videos. Hopefully I'll be getting into tig welding soon. Your videos on spray arc aluminium welding helped me a lot.

As always-I'm speechless and adore your attitude! Each job is a work of welding art! And very educative, too!

Another excellent video. As always, you provide the best welding videos online.

Love the videos definitely one of my favorite channels on here you spread so much helpful knowledge I just wanted to thank you for doing what you do .

Thanks for the video! You guys make it look easy....I've found that it's anything but! The more I practice, the more impressed I get. Your tips for practice, like padding small plates, have been useful. Ditto for the J F Lincoln Foundation recommendations...been reading the books, browsing the project ideas, and waiting for some practice kits to get here. Thanks for the info, the references, and the stubby bundle! -- Mike

As usual very well presented, thanks Jody. You are the only go to instructor in my opinion, keep it up.

I can't stop watching your videos! I can't wait for my 210 EXT to come in so I can practice.

thanks for yet another lesson on how to tig weld aluminum. im based in south wales UK. im learning just from your videos.

Hey Jody and Roy. Great video once again. Would like to see more of these thin aluminium tubing and plate welding tricks videos. Keep up the good work. Cant wait the next video...

hey Jody just wanted to give you props bud I'm a father of 3 kids and married I recently landed a aerospace job 2 months ago that required welders to pass a 6g aluminum pipe test on 6061 aluminum 3" pipe .065 this particular video really helped me with my starts and stops on this test.it was not a easy test but I just passed it the other day they cut 4 sections out of pipe and bent those and the end result was flawless thanks for all you do

you are good at explaining and i really appreciate your efforts and thanks for the video and outstanding commentary.

Enjoy your video’s. Speaking from experience, most people don’t know how much distortion and shrinkage can happen with weldment’s like this.

First time I've heard cut tube called pie cut. Always been Lobster back to me. Always enjoy your vids Jody. Carry On.

Jody, another true master, now I know there there are at least two... Great video, shows some great technique your channel is one of the best out there. Keep up the top notch videos I have learned so much for you.

i have been watching you for 5 yrs now thanks for the time you spend and sharing your knowledge i do also get your cds shirts and tig fingers. Im constantly refering pepole to your site its the best one out there,

Awesome work, thanks for taking the time to do this. I'm learning a lot!

been a subscriber for a long time. Been waiting for a vid like this as I've tried this before and ended up making a mess. I'm just a hobby welder who likes to work on autos and would like to build turbo piping systems. It definately is one of my weak points on the TIG. It really helps when I watch your vids. Thanks Jody!

Thanks Jody. The stab and swirl technique worked really well for me on some 0.032" walled aluminum tube. Very tricky stuff at 3/8" o.d. After a few days of fustration; 25% balance, 17-20 amps, 90 Hz frequency seemed to work nicely. The correct frequency and balance made all the difference.

Excellent tutorial. Thank you for sharing your knowledge and experience.

Another addition when welding angled joints is to weld the outer radius first. This holds the angle better as welded joints always want to tighten to the inside radius.

Thankyou, it's rare to see a video of welding thin alloy pipe. I learnt a lot. I always seem to have trouble "horse shoeing" a hole out between the two pieces. Oh and thanks for quoting some of your sizes etc in metric. Now I and everyone outside of usa know what you're talking about. Cheers

Good vid, thanks. Got to get my hands on a Tig and start teaching myself as they obviously have a lot more uses than my mig welder.

Great to see that Jody - bet he needed the TIG finger! That is one heck of a long job with huge positioning aspects. Lovely work. :) Great video.

Jody - wow, nice work on this project. Looking forward to many great projects this year. Picked up a M 211 at SEMA. Nice machine. Hope you can demo one in the future.

Great Video! Learned a lot! Thanks for all the metric measurements!!! Greetings from Germany! ;)

Love the automotive application Jody

really really nice. 1000 thumbs up for this job and documenting it for us!!!

Great video Jody, thanks for sharing I always learn alot from your videos.

Jodi, amazing videos. Thank you very much for the great content.

Hi Jody thanks for another great video with great tips and info on the settings you use. 👍

Yeah great video great description of settings etc. I'm trying to get a handle on my 255 EXT have never TIG welded before. Seeing these settings and your descriptions will help me get in the ballpark, at least on 16th inch material trying to do butt welds. I'm sure I have watched this one before, today however I think I've watched it three times. ⭐⭐⭐⭐⭐

Jody thanks for sharing your experience with all us your tips have helped me out so much at in my business thanks!

Yes! Thanks Jody! I tried the tapered tungsten this evening on 0.065" Al intercooler tubing doing butt joints. It's much easier to strike an arc and get a tack than with a balled electrode. I'm using 1/16" 2% Thoriated (need to try lanthanated) and 1/16" filler rod. I put a dab of rod on each side of the joint and then try to heat them both up and add another dab of rod to join them. Then use the heat to spread out the weld so it's not so high.

Another excellent video. Thank you. Look forward to the waveform video.

best welding videos in existence

Mate I could watch this stuff for days on end.

I have found laquer thinner to be much more effective on tape residue and tape left on a long time. Great video as usual. You may force me to install video in my shop! I added TIG to my arsenal last year and don't get much time on the torch as I mostly use the mig machines. I have learned a lot from your channel. Happy New Year to you and yours. Doug

This is awesome, I'd love to see you do more automotive welding, since its what I do, also it would be awesome to see you do a stainless exhaust header.

Best instructor on the web

I always have problems tacking aluminium. Next time I will follow your tips. Thanks guys, great video!

Nice video! Thanks for including metric too!

Very knowledgeable at your skill . Keep the tutorials comming..

Great video and I agree on so many points. I just did an air intake with pre bent aluminum with only a few pieces. So not nearly as complex. I'm not as versed on aluminum so still feeling my way through it. Of course not cracking is crucial. Watching the up close I was just wondering about penetration. When I did mine I was worried about cracking potential so I was always slower to add filler. But once its going it moves pretty quick and consistent. If say a bit quicker than in the video. Anyways I hope mine holds with no leaks. My welds at least look good and held 40psi. But the one you made here looks sweet

Howdy. I'm a new subscriber and i like what you're doing here. Keep up the great work! Can you do a series on Structural welds with Dual Shield? I'm just getting my start in the steel industry. We use mostly A36 mild steel. Mostly wide beams and flat plate, some square tube. Very interested to see what you can teach me so that I can pass company certification tests. Thanks for having this channel. I will be watching more of your videos as time permits. Cheers!

Thanks, for all your Videos! The Videos are better Teacher, than such a 'Weldingexpert' how told you only 'trying-trying-trying'. Try to start with Aluminium this week. Keep on Dude, best regads from Germany.

Although Everlast calls it "triangular" that is actually a "sawtooth" waveform. It is generated by an integrator circuit which is composed of capacitors and resistors oriented parallel to each other and the time constant they have affects the slope of the waveform. Great videos and keep doing what you do!!

Cool collaboration with s1.

Great class. I'll be watching soon Thanks Mike

thanks for sharing! happy new year!

Roy did a nice job , that type of work was my life for a number of years , I was a model maker for Delphi thermal systems , HVAC automotive proto type TIG welding aluminum heat exchangers , experimental radiators , heater cores , condensers , evaporators , jigs & fixtures and all types of fittings and component parts , it takes allot of practice and technique to weld thin aluminum to thick all shapes and sizes with out bubbling the inside ,if you had small thin wall parts to be welded such as tubing that cant have restrictions inside you had to be very carefull on the peddle and amperage setting ,4043 filler was my go to rod . stainless steel and inconell types of steels thats another story , gas lens as opposed to a standard nozzle , my preference was a number 5 cup with a 1/16 dia pure tungsten but a gas lens was nice for a deep corners , you can stick that tungsten out of the cup 3/4 of an inch if you had to and still have a good amount of shielding gas , also a #20 water cooled torch was the way to go , also AC balance is a great machine feature for small intricate welding , thanks for posting .

Great video you made this very easy to understand

I thank you devote the time to share tour experience and I wish you a year full of heath and prosperity for you to continúe sharing you knowledge

Another great video. I appreciate the tip

Some great tips in this. Thanks!

Great channel, glad I found your channel sir :)

Great Tig welding aluminum..Thumbs up weldingtipsandtricks

Very nice, thanks for sharing PPO out 😎

Beautiful job

I've just done some of this on down piping. I had hundreds of them to do.

Thanks for the lesson!

great stuff cody. thanks.

Hello Jodie, always enjoy your videos and even after 30+ years of fab work, still pick up something every time I watch one. On this one though, I will have to say...... that's probably the most ridiculous and over-worked method i've ever seen for building a multi bend pipe. Mandrel bends are easily found and the amount of welding would have been reduced by about 75%, not to mention a way stronger and attractive finished product. Just my 2 cents, to each his own....... thanks again for sharing.

thank you for all your information...

Good work, Jody and Roy! Here are a few of ideas for future videos that I think would be neat to see: -Tips for stick welding cast iron with nickel based electrodes -Tips for Blueprint reading -Maybe some arc-shots of TIG welding Titanium, cast aluminum & magnesium alloys -MIG pulse for Aluminum, Stainless, Metal Cored, and Hard Wire Happy New Years, and greetings from Canada! :-)

thank you very much

Another great one!

Very nice. Learning so much

really nice video! I tryed to weld pie cuts before i ve seen this video.... it was horrible :D i will try it again :-) thanks for this video greetings vom germany

Amazing video, thank you!!!

thanks this is the video i was looking for.

I find a chain vice on a v block works amazing for holding odd shapes. That way you can just rotate it . Awesome video

Is there any way you could do a short video on how to make the pie cuts themselves? thank you for your videos they're always helpful and helped me get through welding school.