How to Repair an Aluminum AC Line

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Air conditioners have many parts that require routine maintenance. Among them are the condenser coils, which should be cleaned on a regular basis, as well as the drain line, which ought to be blown out every four to six months. Some components are built to last the life of the unit, such as the compressor and condenser, while minor parts such as the aluminum lines can become damaged through normal wear and tear. Repairing an aluminum AC line is a relatively simple job.

Things You'll Need

  • Steel wool pad
  • Welding goggles
  • Gloves
  • Propane or acetylene torch
  • Aluminum flux weld
  • Microfiber cloth
  • Clean the aluminum AC line with a steel wool pad. Scrub until the bare aluminum shows through and no dirt or grime remain on the line.

  • Light a propane or acetylene torch. Allow it to heat up for five to seven seconds and hold it 4 to 6 inches away from the aluminum AC line. Heat the aluminum line by waving the flame up and down, back and forth.

  • Melt aluminum flux weld onto the AC line where the aluminum is cracked or a hole has appeared. Allow the aluminum flux weld to drip onto the broken part of the aluminum line. It will quickly repair the compromised part of the AC line and patch it with a like color.

  • Let the aluminum flux weld cool for about five to 10 minutes, then rub with a microfiber cloth to polish the patch.

References

  • "Welding Fabrication & Repair: Questions and Answers"; Frank M. Marlow; 2002
  • "Aluminum Welding"; N.R. Mandal; 2001
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