Easy aluminum frame brazing - stronger, more efficient designs

Hadez411

Well-Known Member
Hi all,

I noticed that a lot of the builds out there are being screwed, riveted and bolted together. Brazing aluminum is very easy as far as welding things goes and there are a ton of very well explained videos about how to do it. I've linked one below. You just need some brazing rods from a hardware store, a propane torch, brass brush and a metal clamp/vice.

The benefits are that it's stronger, there are fewer obstructions (less catching, easier to clean), the overall size is smaller and less aluminum is used. It conducts heat better and you can customize your U-channel heat sinks to have add-ons for more surface area. An idea I had was to use left over cut-offs to make little crosses where each cob was located, decreasing the distance heat has to travel before it reaches enough surface area to dissipate. That's something a lot of people don't factor in to their home made heat sinks. If your heat has to travel a long distance to reach the surface area it needs to dissipate, it's going to cool less efficiently than if the surface area is all nearby and in the direction of natural heat flow (up) as opposed to U-channel, which is sideways. Convection is important too, so I'm weighing the option of a series of 1/8" drilled holes in the U-channel. The better you make it, the higher powered cobs you can put on it, so to each their own.

 

BuddyColas

Well-Known Member
Hi all,

I noticed that a lot of the builds out there are being screwed, riveted and bolted together. Brazing aluminum is very easy as far as welding things goes and there are a ton of very well explained videos about how to do it. I've linked one below. You just need some brazing rods from a hardware store, a propane torch, brass brush and a metal clamp/vice.

The benefits are that it's stronger, there are fewer obstructions (less catching, easier to clean), the overall size is smaller and less aluminum is used. It conducts heat better and you can customize your U-channel heat sinks to have add-ons for more surface area. An idea I had was to use left over cut-offs to make little crosses where each cob was located, decreasing the distance heat has to travel before it reaches enough surface area to dissipate. That's something a lot of people don't factor in to their home made heat sinks. If your heat has to travel a long distance to reach the surface area it needs to dissipate, it's going to cool less efficiently than if the surface area is all nearby and in the direction of natural heat flow (up) as opposed to U-channel, which is sideways. Convection is important too, so I'm weighing the option of a series of 1/8" drilled holes in the U-channel. The better you make it, the higher powered cobs you can put on it, so to each their own.

Great video.
Thanks for sharing.
I have only used bolts and rivets...'till NOW!
Inquiring minds would like to see some of your frames.
 

Hadez411

Well-Known Member
Great video.
Thanks for sharing.
I have only used bolts and rivets...'till NOW!
Inquiring minds would like to see some of your frames.
Stay tuned for updates on my 5 x 15w COB bar. I've welded aluminum angle iron before so this should be a cinch.
 

Hadez411

Well-Known Member
Yes, never breath metal fumes. They cause pneumonia and sinusitis as well as long term damage.
 

1212ham

Well-Known Member
Never ever try to weld / heat galvanized metal it will give off mustard gas that shit can kill you!
I don't believe that, can you provide any documentation? Welding galvanized does put zinc oxide particles in the air, not good to breath.

Welding chlorinated brake cleaner or other things with chlorine produces phosgene gas, that shit will kill you!
 
Last edited:

Hadez411

Well-Known Member
Damn, alright. Kind weird all of our air ductigs made out of it....
It's super stable at normal household temperatures. If you heat it to welding temperatures (600+ celcius) it will make a yellow gas that is going to be caustic to your lungs/nasal passage and and lead to headaches, sinus infections, pneumonia etc.
That's why most venting is crimped and folded together, a lot of it is galvanized so it doesn't oxidize.
 
Last edited:
Top