I have heard it's possible, but not easy to make quality aluminum welds with SMAW (stick welding). A quick search brought up Harris alloy #26.
http://www.harrisproductsgroup.com/consumables/catalogsection.asp?Category=alum_elect
Give it a go, and let us know how it works.

 

A couple of years ago a guy gave me 3 Al welding rods. Ran them. I have pictures but my attachment button won't work.

The beads were not pretty, though no problem with burn through or adhesion. They are a mess to clean up after. The flux is like that of brazing. I don't know how good they can get since I only had three rods.

Ran it reverse polarity. Too much current and spatter the size of pea size hail flies and hits you in the top of the head.

I ask my vendor to let me try them and he gave them to me.

 

Well, it looks like I will have to go down to airgas and see what they have, thanks for the help!

 

I've used the Lincoln Aluminum stick rod, and it sure does make a mess. I think you can only run it DCRP, and it burns REAL fast. You'll get about 3"-4" per rod. It's inexpensive, so that's a plus. Not the prettiest, but if you're outside and in a jam, it'll work. Other companies also carry it, and it welds nicer, but it's pricey. I think you are out of luck on AC though.----john

 

Only good for horzontal beads, out of position is a no-no. I wouldn't expect much with an a/c welder, AL should be welded d/c reverse polarity. I've done it and had no problems. Good luck!

 

welding aluminum with a stick,:realmad: will make you go buy a tig in a hurry.

 

I once repaired an aluminum chainsaw handlebar with a stick welder, also an aluminum cattle trailer, works pretty good, but you have to use DCEN it can lay a pretty nice bead. Just keep the amps down and make sure your metal is CLEAN. as for taking the flux off, yea that sucks a little acid and a wire brush does the trick