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12-25-2004, 04:49 AM
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CC Member
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Join Date: Dec 2004
Cobra Make, Engine:
Posts: 16
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Not Ranked
Shaping aluminum bodys
Hi I am currently in the process of building a prototype car and would like to know what grad aluminum to use how thick and how you go about shaping it
Thank you
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12-25-2004, 07:43 AM
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CC Member
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Join Date: Sep 2002
Location: Tucson,
AZ
Cobra Make, Engine: ERA 427" 351W
Posts: 562
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Not Ranked
I know it's Christmas and let me preface this by wishing you a Merry Christmas! Don't you think this might be an undertaking that is a bit beyond your expertise? I gleaned this from your post but I may be all wet, have at it! Call Dr. Phil!
__________________
Al W.
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12-25-2004, 07:48 AM
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Senior Club Cobra Member
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Join Date: Oct 2000
Location: Las Vegas,
NV
Cobra Make, Engine: Kirkham#182/Shelby 496c.i.
Posts: 756
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Not Ranked
__________________
"You can NEVER teach a pig to sing! You'd just be wasting your time and annoying the pig!"
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12-25-2004, 08:05 AM
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CC Member
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Join Date: Nov 2003
Location: New Britain,
CT
Cobra Make, Engine: Size 10 Feet
Posts: 2,993
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Not Ranked
See here for some hints... |
12-25-2004, 07:38 PM
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CC Member
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Join Date: Dec 2004
Cobra Make, Engine:
Posts: 16
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Not Ranked
Thank you for the response as for "thorconstr' I could do without your smart ass response.
Also what grade aluminum is used and what is the thickness
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12-25-2004, 09:55 PM
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CC Member / Sponsor
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Join Date: Jan 2002
Location: Provo,
UT
Cobra Make, Engine: Daytona Coupe
Posts: 1,356
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Not Ranked
Typically 3003 or 1100 at .060" is used.
Forming methods:
English wheel, British Sports cars.
Hammer form (often just a tree stump), Italian sports cars of the '60s.
Power (Yoder) hammer, Kimmons Coach works (built several Cobra bodies for Shelby. Also has restored several original Cobras)
Another more modern method is superplastic forming. Panoz, Morgan and Ford GT form their bodies this way. This type of forming also requires the use of special alloys.
I do not know how the new Audi, Jaguar, and Ferrari are made. I suspect they are pressed.
Bodies are typically gas (oxy actelene or oxy hydrogen) welded together. TIG is too slow and brittle.
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12-26-2004, 07:08 AM
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Senior Club Cobra Member
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Join Date: May 2001
Cobra Make, Engine: A CSX Cobra,1966 GT350 and an '06 Ford Heritage GT
Posts: 1,829
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Not Ranked
lj;
Having been teaching myself a little bit at a time, might I suggest www.tinmantech.com as a starting point. Lots of instructional stuff, as well as tools and even some classes. Also, look for some videos by Ron Fournier, also very good. For inspiration and knowledge, check out http://members.aol.com/coupechuck/
For tooling, you can find pretty good deals on Ebay, just search for "English Wheel' and you always get quite a few hits. I bought my big floor model from OklaHdwr on Ebay. I have been very happy with it, 8" x 3" wheel and large enough to put in a 4' panel if you want. I paid about $2200, and that is WELL below retail.
As for smarta$$es, I guess it goes with the territory 
Anyhow, start small and good luck! Don't forget to post a few pics.
__________________
"I think we have more machinery of government than is necessary, too many parasites living on the labor of the industrious." Thomas Jefferson
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12-26-2004, 08:36 AM
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Senior Club Cobra Member
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Join Date: Sep 2003
Location: Dawsonville,
GA
Cobra Make, Engine: 302 done, CSX289 comp body, leaf spring chassis to original specs...
Posts: 899
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Not Ranked
Don't you think this might be an undertaking that is a bit beyond your expertise?
I have been told this a few times in my life also. Each time I have heard it, it pi$$ed me off. To this point it has yet to hold true. 
We are a pretty smart bunch. With a little homework, a little patience, some help from others, and a lot of persistence I know I can do just about anything. I am sure you are no different.
I wish you the best of luck and hope you post some pictures.
-John
__________________
So you been broken and you been hurt, Show me somebody who ain't
Yeah I know I ain't nobody's bargain, But hell a little touchup, and some paint...
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12-26-2004, 08:48 AM
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CC Member
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Join Date: Nov 2003
Location: New Britain,
CT
Cobra Make, Engine: Size 10 Feet
Posts: 2,993
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Not Ranked
For all the basic-skill and capital investment required to do a one-off in aluminum, you might consider fiberglass instead. Either techniquie requires that you build a buck. You might as well finish the shape of the buck completely and take a quicky mold...
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12-26-2004, 12:49 PM
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CC Member/Contributor
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Join Date: Feb 2000
Location: Greenville,
SC
Cobra Make, Engine: 70 Shelby convertible, ERA-FIA, 66 mustang convertible, mystery Ford powered 2dr convertible
Posts: 12,627
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Not Ranked
thorconstr,
The guy is a newbie with no sense of humor. Must be an Australian thing 
__________________
Instead of being part of the problem, be part of a successful solution.
First time Cobra buyers-READ THIS
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12-26-2004, 01:46 PM
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CC Member
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Join Date: Sep 2002
Location: Tucson,
AZ
Cobra Make, Engine: ERA 427" 351W
Posts: 562
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Not Ranked
It is one hell of an undertaking, and I was trying to be funny! As for the body, I believe that after all the equipment, junk pieces of aluminum in the corner and man hours ( you have to figure your time is worth at least $50.00 per hour unless your a lawyer, then it's worth $200.00 and up). The body will most likely cost about $100k conservatively. Kirkham's # is 801-377-8224. Tom, Dave, Steve, great guys, or Mary, their very well informed Mother. One heck of a deal when you think about it! And, my wife says that I am a "Sarcastic Curmudgeon", I believe that is an older more sophisticated wiseass! I truly did not mean to make you unhappy, have a great New Year! And call Dr. Phil!
__________________
Al W.
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12-26-2004, 02:14 PM
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Club Cobra Member
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Join Date: Feb 2003
Location: SF East Bay,
Ca
Cobra Make, Engine: SPF
Posts: 499
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Not Ranked
I see two others have posted links to Chuck's coupe and that is where I would suggest going too. Since he has gone through everything you are about to embark on he would be a great place to start asking questions.
__________________
We have enough youth. What we need is a fountain of common sense
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12-26-2004, 06:54 PM
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CC Member
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Join Date: Dec 2004
Cobra Make, Engine:
Posts: 16
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Not Ranked
Thanks guys that will be great and help save lots of time with the your guidance sorry "thorconstr" I have bean finding it hard to get assistance from people in other web sites thanks for you help too
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