Questions about soldering sheet metal

[zeturi]

Soldering is similar to welding, I know, so I'd rather not even learn to weld unless it's totally necessary for my application. I'm going to get several sheets of aluminum cut to size with a router, and I would like to join the sheets together at right angles.

I don't want to do JB Weld, bondo, or superglue unless it's on the inside, where it can't be seen. Even then, I want to try to make a smooth looking bond on the outside, hopefully using solder so it keeps the metal appearance. If it ends up uneven, then I can just sand it down with a sanding belt.

But yeah, question is, can I solder aluminum sheet metal together at right angles, rather than weld? Anyone with metal work experience (ßeta, Jlee, Robm, possibly others?), I would appreciate any input.

 

[bud]

Mario solders n64 shielding together. That's aluminum right?

 

[zeturi]

Whoops, I meant a thicker kind of aluminum, shielding isn't strong enough to be used as a casing. I'm think more along the lines of 1/8 or 1/16 aluminum.

But yeah, Mario did use that to strengthen mount his cartridge slot in Stella....

 

[samjc3]

Should work. It would just take a Heck of a soldering iron. Probably be a good idea to use silver solder too.

 

[Bush]

And get that sucker nice and hot. you may also use some flux, as oftentimes solder without it will fall off of fairly new and clean metals (like pins on a TI reg)

 

[samjc3]

Speaking of "new and clean metals," be sure to rough up your edges pretty well. It'll help the solder hold.

 

[zeturi]

I"m also gonna sand it really rough, so I get some grooves for the solder to cling against.

 

[vskid3]

Who is cutting the metal? They might have experience. Or just get it bent, then you only have one unconnected corner to deal with.

 

[zeturi]

Actually, I just thought, why not get the aluminum sheet cut into a "t" shape, then have all the edges bent up? Then, I'd just have to solder the corners, which'd be easy, and then I could have a flat piece to cover the top.

Thanks for the idea, vskid!