On Jan 24, 9:05*pm, "
wrote:

Neither do I know how to weld aluminum to steel, but I have used a
steel or copper plate to flow melted aluminum from a MIG onto as sort
of a "cast as you go" way of building up aluminum for further
welding. *It might work with a TIG as well?
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Yes, it does. But I don't know how I could maintain the required
clearance as the 'tunnel' advanced.

There's a strong possibility we are looking at the job from entirely
different points of view. My lack of skill with TIG reflects my lack
of experience. 'Coppering' is fairly common with TIG for automotive
sheet metal repairs but I've never seen a copper with that amount of
curvature. It will take virtually a solid bar to handle the amount of
heat needed with aluminum.

This will sound a little crazy but in my head I've linked the Chugger
project with the cancer, in that success with one means success with
the other.