Aluminum Body Experiment

[rbray]

For the last few years I’ve been playing around with metal working and I’ve decided to conduct a few small trials of building an aluminum body from scratch.

Here is my progress to date: http://picasaweb.google.com/rbrayzz/MetalWork#

I’ve used the front left fender of my EM as a pattern to make a small wooden buck. The fabrication is being done with an English wheel a sand bag and mallet and a lot of time.

For Christmas I got an aluminum welding setup that I plan on learning to use this summer. I have a friend that is a professional welder who is going to help me get started.

I also have a mandrel tube bender that I don't know how to use yet, but it should be fun learning.

The results to date not perfect, but they are much better than I expected on my first try.

My plan is to spend this summer practicing fabricating and welding some panels and then decide if I want to commit do doing a full scale project.

[Ozgur_Tan]

hey roger
nice work
i'm planning carbonfiber main body hull and aluminum hood, trunk and doors for my scratch built 289
you may take a look my built this particular sub-forum
regards
ozgur@istanbul

[RedBarchetta]

Wow...impressive! And you don't even speak Polish!

-Dean

[Terry Stapley]

But when he is finished forming the aluminum he will need polish!!

Nice work - keep at it!!

[rokndad]

Holy C**p!! I'm really impressed with that work. Stunning progress. Please continue to post and show us your progress. What gauge aluminum is that? That English wheel is really a great tool.

[mickmate]

Looking good, when you're ready to try welding the aluminum try it on larger panels that dissipate the heat better. The glasses are really key also, while ally doesn't get red hot the right glasses let you see the puddling and melting point.http://www.fournierenterprises.com/c...8&cat=0&page=1 You go man, and as Tom said keep us posted.

[RedEsprit]

Good luck Roger. Work looks great so far. I am currently making an aluminum hood, doors, and decklid for my ERA. (Turning it into a hybrid) For what its worth, I found the key to welding the aluminum is in making sure you continuously dab the rod into the puddle...and keep moving. The "cold" rod sets the weld and keeps you from blowing holes in all that hard work. I use a Henrob2000 (DHC) which makes welding a lot easier. Ron Fournier at Fournier Enterprises has some excellent video on welding sheet aluminum by the way.

[CobraBoy]

Great work, Roger! You don't fancy doing one for me, do you...? As the others have said, make sure you keep us posted.

Paul

[rbray]

I've been putting in quite a bit of time on my little experiment.
Here are the updated photos: http://picasaweb.google.com/rbrayzz/MetalWork#

Most of the pieces have been reworked or replaced.
Even though I'm years away from learning all the skills need to build an aluminum body, I'm having a blast learning!

I bought a Hebron gas torch and I've taken my first crack at welding aluminum.
It was no surprise that all I managed to do was melt some scrap metal. The good news is that I have several instructional videos to study and I have lots of patience.

If anyone wants to try to do some metal work I recommend buying Ron Covell's video "Shaping Aluminum with hand tools". For about $50.00 bucks you can buy the tools you need and get started. Metal shaping really is a fun hobby!

[mickmate]

I hope you're as inspired as I am by looking at what you've accomplished Roger.
I was just reading the Henrob is kind of heavy and awkward and I found that myself using one, the Meco Midget is small, light and highly recommended, I want to try one of those.

[Rick Parker]

Several years ago I went to a prduction shop that used a small scale gas torch to weld aluminun tubing while making tuned pipes and mufflers for RC scale model aircraft. I was familiar with TIG welding but seeing a torch used, and the finished product was an entirely new art form.

[PatBuckley]

My hat is off to you!

Way to go.

[PDUB]

Wow! Very impressive