On Tue, 14 Sep 2010 14:06:46 -0700, Tim Wescott
wrote:

On 09/12/2010 05:13 PM, Tim Wescott wrote:
I'm kinda thinking of making a model airplane muffler or two. These
days the things are generally cast in one piece -- but that isn't going
to work for a one-off.

These things have a header that comes off of the engine, then goes into
a tube-shaped expansion chamber. See some examples he
http://www.mecoa.com/kb/aero/aircraft.htm

I'm thinking that I can fabricate one of these with a machined header,
machined ends, and a section of tube. But it'll all be aluminum, so how
to join the pieces?

I'm assuming that JB weld won't take the heat and will just fall off.
But I'm ready to be corrected.

I don't have a TIG welder, or I'd just select TIGable materials and be
happy.

I do have an oxy-acetylene set, and I certainly know how to solder.

So -- will aluminum brazing work on this? What sort of selection do I
have as far as difficulty vs. results goes? Brands to look for? Avoid?
Places to get stuff? I'd like something that's going to be as strong (or
nearly so) as the parent material and that can be done on a welding
bench with a torch and a vise.

TIA.


Update: the local welding shop has an aluminum soldering kit and
aluminum brazing flux, but was out of aluminum brazing rod. They had
some zinc-alloy rod that may or may not have worked with the aluminum
brazing flux, in a size way bigger than my job.

So I got the soldering kit.

I'm going to see how well the soldering process works -- if it seems
almost but not quite strong enough then I'll try brazing, if it works a
charm I won't change.
I've got about 3 lbs of AluSol sitting in the garage - flux cored
solder for aluminum.