What type of welding works for Zinc Aluminum (Pot Metal)? Or is it impossible/too hard?
I wanted to customize the angle of my handlebar side mirror clamp, so I cleanly split it in half using a wire-cut machine. Now, I'm stuck trying to figure out how to put it back together at my new custom angle.
I took it to a few local shops and got turned down:
- TIG Welder: Said the metal is too thin and would just melt.
- Radiator Shop: Said it’s made of a zinc-aluminum mix, and standard brazing would possibly melt the whole clamp into puddle before the welding rod even melts.
The clamp doesn't hold any heavy structural weight—it just holds the offset side mirror mount.
What are my options here is there any other forgiving welding method for this? My absolute last resort is just to drill a hole and put a screw through it to hold it together, but I'd prefer a cleaner look if possible. Any advice on what to do with this shit?
EDIT: Thanks to everyone's comments, I've realized brazing or welding this pot metal is a recipe for disaster. I'm going to look for a 3D modeling/CNC machinist to get this custom clamp made properly instead. Thanks y'all!