HP-2116A chassis (or repairing cast aluminum)

[gordonjcp at gjcp.net]

> Tim Riker wrote:
>
>> 3) Thoughts on repairing the chassis? I could bondo, superglue, epoxy,
>> silversolder, etc. the pieces together, and add a plate behind it
>> attached with countersunk screws. Would not be very visible once the
>> panels are put back. I have the two side panels and the bottom panel,
>> but no top panel. Thoughts on which would work best?
>
> I think your best bet is welding.  I believe that welding aluminum
> requires special equipment.  A guy at my office does something called
> TIG welding for his robotics projects.

It is indeed TIG welding.  You strike an arc between two tungsten
electrodes, shielded by an inert gas.  Hence, Tungsten Inert Gas welding.

> I think the weld can be sunk
> into the material and ground smooth afterwards, giving a nice
> appearance.  It will probably be expensive to have this done, however.

Not sure about cost.
In all welding, the weld should penetrate right through the metal,
otherwise it's just a snottery blob on top that won't hold anything.  It
should be possible to grind the weld flush without weakening it.

Gordon.