Welding Tips and Tricks

Hello everyone,

I'm in the process of making plans for a roof rack (for my van) and saw this video but the maker is not saying what material he is using (nor is there a contact) - I think it's 1.5 inch but would like a 2nd opinion.

Also, it looks surprisingly light as 2 people can handle it without a problem, do you think it would still be the case if it was made from steel?

I was going for 1.25 diameter initially. I think I will buy a piece of long stock in both 1.25 and 1.5 inch and put them up on the van temporarily to see which looks better (aesthetically proportional to the van size)

Here is the video (ignore the welding, it's his first time) https://www.youtube.com/watch?v=Nh4x3Y9MQT8&t=106s

Thank you

I’d guess 1.5”x0.125 wall thickness

cj737 wrote:I’d guess 1.5”x0.125 wall thickness

I was thinking the same; many thanks once again!

.095” thickness is also completely adequate for roof racks and it saves ~25% in weight compared to .125”.

That is aluminum. You can kinda tell due to its dull finish.When he is cutting it with a hole saw it throws teary chunks, and when he cuts it with the cutoff wheel there are no sparks.

bap_ wrote:That is aluminum. You can kinda tell due to its dull finish.When he is cutting it with a hole saw it throws teary chunks, and when he cuts it with the cutoff wheel there are no sparks.

And they’re using a spool gun which is a no brainer for mig welding aluminum.

Hah ya that'll do it. I didn't even notice, I skipped to the middle/end right off the bat.

Also the title of the YouTube video says aluminum


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I submit hah

1.25 or less. Even with long fingers they wouldn’t wrap around that far on 1.5. Old pipe fitter trick. Try it.