• Hi Guest! Being a Paying Supporter is NOT a requirement to participate at BCF. However, subscribing will help ensure we can continue to serve the LBC community for years to come. If you enjoy BCF and find our forum a useful resource...Please consider supporting us by **Upgrading**
    (PS: Subscribers don't see this banner)

Filler metal used for tig welding ah aluminum shrouds


Freshman Member
Can anyone tell me what filler rod works best on the aluminum shrouds on an AH 100-4 or 6 / 3000. I have a lincoln 175 square wave machine.




Hi Marc,

The best I could make out was that the parent metal (Birmabright) is supposedly NS4. The general recommendation seems to be to weld it with 5356 rods. Search for welding birmabright as there is a fair bit about it on Landrover forums.

I had a bit of a debacle TIG welding my rear shroud. A friend here is a very good welder so I got him to do the welding which he had quite some trouble with due to dirt in the metal. The main issue is that wherever you weld will crack right afterwards if it is ground flat. After a few attempts at the weld, grind, crack game, Steve left his welder with me and just said keep welding until it stops cracking. The technique I found to be most effective was to lay a fairly large bead on top and melt it down to just above flush, then turn the shroud over and grind out most of what had come through but leave a smooth mound about twice the parent metal thickness. If there is still a depression or line down the middle on either side after grinding then it will crack there shortly.

Definitely need a foot pedal on the welder and a stainless steel wire brush in a battery drill to scour the metal right down until it is completely shiny. Hand wire brushing was nowhere near effective at removing all traces of oxidisation.



Jedi Hopeful
Country flag
Hi Marc,

I didn't know of the Rover site, and it being called Birmabright, nor using the 5356 rods, but instead was using The Tinman's recommendations. His site is: https://www.tinmantech.com/html/aluminum_welding_supplies.php of which I've purchased several videos. He does his repairs the old way, using gas. But using TIG is even better, of course. He recommends using ER-1100 and will sell it to you in a roll, 3/64 diameter. I used it in patching some cracks and body grind through, on my BJ8, as well as patching the holes in the rear shroud where the hinges mount. The aluminum is very dirty, as Andy mentions, and the darn stuff will oxidize in 20 seconds after you clean it...or so I remember from the videos. I didn't have any cracking issues when I did mine, but the stuff is so thin, you have to be very carful of over heating and dropping out a puddle of aluminum. I used the .040 tungston tips, and 3/8 or so cup and kept the heat down low (I have a Miller 165 diversion, not a high freq machine, but it seems to work). I didn't use any flux with the TIG, but I think that may help too. In talking with a welder at work, one who has experience with aluminum, he said to melt the metal on the edge, just enough to get the impurities to float to the top, then clean and repeat until no impurities are there then weld to that spot. I was able to fix the cracks and holes and so far, knock on aluminum, no cracking....
Similar threads
Thread starter Title Forum Replies Date
S TR2/3/3A TR3 gas filler cap Triumph 1
R TR6 Looking for Oil Filler Cap TR4/TR6 Triumph 7
ckeithjordan TR2/3/3A Gas Filler Cap Triumph 1
Chuck9482912 Rust in new fuel filler neck Austin Healey 4
BlueMax TR2/3/3A No Body Filler On This TR3 Triumph 7
Jim_Gruber What Now, new gas tank filler neck is about 1/2-3/4" too short Spridgets 19
maxwedge5281 gas filler opening replacement Austin Healey 4
C TR4/4A How to get the $&@%# filler bolt out of the side of the trans to top her off?!? Triumph 7
bugedd Aston filler cap Spridgets 8
TRMark Body Filler Mixing Board on the cheap Restoration & Tools 2
T BSW Filler Plug Armstrong Rear Shocks? Spridgets 2
maxwedge5281 gas filler and cap options Austin Healey 9
maxwedge5281 monza fuel filler door??? Austin Healey 6
S Embarrassed to ask: Transmission/Gearbox filler location on BJ8 Austin Healey 14
S TR2/3/3A fiberglass filler Triumph 4
Rut Body work and filler Spridgets 2
steveg Steering box filler Austin Healey 0
andrea OIL sprayed on the under hood-TOP oil filler indaghed Austin Healey 26
D Body filler brand??? Spridgets 26
Lukens Is this my gearbox filler plug? Triumph 10
T Filler question Triumph 14
tahoe healey Gas filler tube gasket Austin Healey 11
jhorton3 Fuel Filler Hose Spridgets 0
BillD Gas Cap does fit on new tank's filler tube Spridgets 5
bighealeysource Looking for a 100-4 valve cover oil filler cap Austin Healey 0
Jeepster fuel tank filler pipe Austin Healey 8
Jim_Newman Fuel tank filler pipe Austin Healey 4
brgrmyster GT6 Original AC oil filler cap 67-68 GT6 [also TR4A]? Triumph 1
O TR2/3/3A TR3 Fuel Tank Filler Triumph 3
K oil filler cap Spridgets 0
J location of transmission oil filler on a BN-2 Austin Healey 5
E Bugeye Gas Tank Filler Tube Grommet Spridgets 13
DrEntropy Found confirmation of filler cap Lotus 14
A Gas filler cap Triumph 3
J What should I feel at oil filler pipe? Triumph 14
6 Fuel Filler Tube Color? Austin Healey 4
I What do I use to paint filler neck? Spridgets 10
Tabcon Okay...who poured green paint in my oil filler! Triumph 16
fad64b Help with "Filler Plates" Please MG 1
V TR2/3/3A TR-3B Oil Filler Cap Triumph 5
JPSmit What type of body filler do you use? Restoration & Tools 7
A TR2/3/3A TR-3A Gas filler cap Triumph 2
CharlieCarpenter Gasket for oil filler cap??? Austin Healey 1
ncbugeye What tool to remove final drive filler plug? Spridgets 12
G Oil Filler Cap-Retaining Wire Austin Healey 11
mjobrien Chassis to Scuttle - Gasket - Filler - Foam? Austin Healey 13
A rambling about my tranny filler plug, again. Triumph 18
H Fuel filler cap Austin Healey 6
T gas filler cap Triumph 12
jpr28056 Fuel coming out filler MG 2

Similar threads