[diyengineer]

Possible to make a sheet metal box out of .063" aluminum 6061-T6 with nothing more then a few tig tacks every few inches on the inside? If i made a jig to hold the box and the pieces were cnc cut, would the box be strong enough? Instead of tacks would you have to do a 1" bead then say a 4-5" space between them..

Just wondering.

Miller syncrowave 200 air cooled torch. I would have to do lots of practicing, but just wondering if it could be done with tacks, or would i have to do small strips. I want the outside to be flawless, and untouched.

[diyengineer]

I would prolly have to back up all the welds with copper bar to asorb the heat and avoid distortion.

[DareBee]

sure - strong enough for what?

[diyengineer]

Strong enough to be a cnc control box. And take some abuse if i beat on it. haha. I dont want it to be flimsy and garbage. I would have sheets of .063" going across on the inside to make smalller compartments to stiffen it up as well.

Sound like it would be a pain in the A$$ to do?

[DareBee]

It would work (but you wont like it).
Usually I double the size that I would make it out of steel for aluminum.
You will get distortion custom welding 16 ga in steel and much worse with aluminum.
I think you would be happier with steel.
FWIW aluminum sheet fabrication is best done with 3003