aluminum ship repair welding?

Just pick a day that isnt windy, then you will have few if any problems. Not sure about doing something like a handrail with a spoolgun though...........weld appearance not likely to be very nice.
k

I take it then you are suggesting he should TIG weld!. Tig will give the best bead appearance only if the person doing the welding has the skill required to do such a weld.
However I would agree with the two replies. Pick a day that is not too windy but also set up some sort of a tent or shield to protect from the wind is about the only way to do this outside. One other suggestion is to do as much fabricating and welding on the handrail in a shop beforehand!
Good luck and let us know how you did!

You will need to get adequate power to the vessel. You know that of course. If you can clean the oxide off with a light sanding then wire brush the surfaces where you will weld using a stainless brush on a small angle grinder. High humidity ( hydrogen) plays havoc with aluminum welding. It might be prudent to preheat the areas with radiant heaters or at least warm up the plating with a small torch before starting to weld. You only want it warm enough so that there is no residual moisture on the material. You will have to rig up tarps for a windbreak. That is not a big problem. Randy
I have been asked to bid a job where I'd have to fabricate a simple handrail of 6061 aluminum and weld it to a guy's boat. This boat is too big to trailer to a shop, well, not in any practical way anyway. That means welding it outside, in the wind.
How the heck do you weld aluminum outside in the wind? I have a Millermatic + Miller Spoolmatic 30A, that's the only way I know how to weld aluminum.
Grant Erwin