Stick welding aluminum is possible and actually works better than I expected. I used 1/8" Harris 26 Aluminum Welding Electrodes that I purchased from Cyberweld.com. The electrodes use different flux than more common steel electrodes, but the process is basically the same. They recommend DCEP/DCRP, which makes sense. AC TIG is able to remove the oxide layer on the base metal during the electrode positive portion of the alternating current. DCEP constantly removes the oxide layer from the base metal while the electrode flux keeps oxides from forming on the electrode metal and the molten pool. The flux protects the weld as it cools and forms a protective barrier, which works great even in windy conditions. They key is to move faster than you would with a steel electrode and not much weave movement is required since the aluminum flows better than steel. I welded a 3"x6"x60" aluminum box section out of 3"x0.125" angle for a storm grate extension and used less than 1 pound of electrodes. That works out to 60" x 4 seams = 240", which would have used quite a few TIG filler rods and a significant amount of argon from my 40cuft bottle. The following video shows the basic process and my newbie welding skills. This bit of welding was done with my Everlast Super250P on a bottom side of the grate extension near the beginning of my learning curve. My welding and my welds got better as I progressed.
Here is the video:
Gunners note: Stick welding aluminum requires you to move FAST as the rod burns down very quickly. Nearly all Aluminum rod will work fine with AC though most recommend DC-
"Lenin called them "useful idiots," those people living in liberal democracies who by giving moral and material support to a totalitarian ideology in effect were braiding the rope that would hang them. Why people who enjoyed freedom and prosperity worked passionately to destroy both is a fascinating question, one still with us today. Now the useful idiots can be found in the chorus of appeasement, reflexive anti-Americanism, and sentimental idealism trying to inhibit the necessary responses to another freedom-hating ideology, radical Islam"
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