Is Welding Worth It?

[InFlight]

On your riveted joints failing. It's very important to use the correct grip length and hole size for the rivets. If your riveted joints are failing constantly, it's likely some sort of installation error.

Welding Aluminum requires either a MIG or TIG welder. This requires some considerable practice, and mentor familiar enough with the equipment to teach others how to use it safety. It can only be used with some types of Aluminum, stick with 6061.

While not as strong as a weld, it is also possible to braze Aluminum with a plumbing torch. I'd only try this with 6061 aluminum and use Bernzomatic AL3, Alumaloy, or Durafix braze rods.