re: Anyone ever stick welded aluminum? (Boat repair/patchwork)

I have. It's not bad if you are using in on thicker aluminum 3/8" and up. Thin sheet metal or diamond plate can be done but is a pain. For thin material I would recommend welding downhill. The aluminum rods will consume very quickly and you only get about half the rod used before it gets to hot.

I would recommend either using a spool gun or heliarc