Friction Stir Welding (FSW) is a simple process involving a rotating tool (with an extended pin) traversing on the joining line of the two work pieces leaving behind the required weld. Tool geometry (pin and shoulder), rotational speed, traverse speed, and tilt angle are important parameters which determine the resultant properties of weld. Milling machines due to rotating tool and traversing can be used as a method of doing laboratory scale FSW experiment. In cases where milling machines have a fixed head, limitation of zero degree tool tilt angle results in substantial defects (e.g. tunnel defect) in weldments. In this study a new approach is developed and adopted for overcoming this limitation of a fixed head vertical milling machine to incorporate the flexibility of tool tilt. The results for welding with and without this approach are presented along with discussion and conclusion. © (2013) Trans Tech Publications, Switzerland.