Aluminum Panels

JOHNNYCOBRA · #1 (**permalink**) 02-04-2003, 03:10 PM

ANYBODY OUT THERE KNOW HOW THE ALUMINUM PANELS
UNDER THE BONNET ARE MADE,(TEMPLET?)

AND IS IT USALLY ONE PIECE?

(ONE BIG SHEET OF ALUM.) WOW!
THAT WOULD COST AN ARM AND A LEG!

Jon Miller · #2 (**permalink**) 02-04-2003, 06:52 PM

Hi Johnny,

I get a little confused when people start throwing around terms like "Bonnet", but I think that you are talking about lining the engine compartment.....I started with a 4'x12' sheet of 2024 T3 .025 Alclad from Aircraft Spruce and Specialty, cost was $158 delivered. I made templates from brown wrapping paper and then cut out the aluminum. I did all of the bending over the edge of a formica covered table. A sheet metal bending break would have been better, but you gotta use what you got. About 1000 pop rivets later I was done. The only change I would make is to use thinner or softer aluminum next time, maybe .015 or .020.

Good Luck!
-Jon

Bob Putnam · #3 (**permalink**) 02-05-2003, 04:51 AM

Jon,

2024 is possibly the worst alloy to use for a non-structural part. It is difficult to work with and prone to corrosion. The best one for the job is probably an 1100 alloy in -0 (dead soft - you can almost put your thumbprint in it) or H12 or 14 (low temper) for more strength.

dkjos · #4 (**permalink**) 02-05-2003, 06:01 AM

I want to throw out a little plug for a great source for all kinds of metals, especially in small quantities. Check on the web for Metal Supermarkets to see if they have a franchisee near you. They stock a huge variety of steel, stainless steel, and aluminum in all sorts of shapes and sizes. The local store will cut to your requirements for no charge and the prices are reasonable. For example, I just got two pieces of 1 x 3 x .087 wall steel tube, cut to 13 1/6" length, for the grand sum of $1.39 each.

Jon Miller · #5 (**permalink**) 02-05-2003, 07:48 AM

Bob, You're right about 2024 being hard to work with, especially without a shop full of sheel metal tools, but mine turned out fine. As for the corrosion problem, that's why I went with alclad. It has a layer of pure aluminum over the top of the 2024. The coating give a near mirror finish and protects from corrosion.

-Jon

NASA/Ames
'90-'91

JOHNNYCOBRA · #6 (**permalink**) 02-05-2003, 07:53 AM

THANKS GUY'S i BELIVE YOUR RIGHT ABOUT THE SOFT
ALUMINUM TEMPER.
I'LL CHECK FOR THE STORE LISTINGS IN THIS AREA FOR THE
Metal Supermarkets

THANKS AGAIN

JOHN