ceebmoj
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| posted on 21/6/11 at 07:54 PM |
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Joggling hole in aluminum sheet.
Hi all,
I want to joggle the edge of a hole in an aluminum sheet so that I can fit a flush fitting panel held in with dutz or simpler fasteners. does any one
have a guide to Joggling or can you recommend a tool? I would like the corners to be radiused, how do you do that?
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jacko
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| posted on 21/6/11 at 08:18 PM |
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http://shop.ebay.co.uk/items/__joggler+tool_W0QQ_dmdZ2?rvr_id=242445078036&clk_rvr_id=242445078036&crlp=982462591_28459
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ceebmoj
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| posted on 21/6/11 at 08:26 PM |
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have just seen them but i'm not sure if they can go round a radius conner.
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jacko
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| posted on 21/6/11 at 08:47 PM |
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No maybe not
How about cutting a hole in a piece of ply wood the shape you want then lay and clamp the alloy on i t.
then tap it to shape
After that cut the center out to leave a flange for the clips
You may have to practice this
Hope you know what i mean
Jacko
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DIY Si
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| posted on 22/6/11 at 07:35 AM |
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For awkward shapes in steel panels I have used a shaped backing piece and then, using an old screwdriver with the end rounded off slightly, just
hammered the shape into the panel. It's best to go gently and take a few passes to get the folds fully formed or you risk ripping the metal.
“Let your plans be dark and as impenetratable as night, and when you move, fall like a thunderbolt.”
Sun Tzu, The Art of War
My new blog: http://spritecave.blogspot.co.uk/
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Fred W B
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| posted on 22/6/11 at 08:39 AM |
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I'd try making a hardboard male and female template that fit together with a gap and hammering them together on a backing surface. Cut the hole
first, but leave a generous flange to be trimmed
after.
Would work best if you could improvise a press arrangment.
Cheers
Fred W B
[Edited on 22/6/11 by Fred W B]
You can do it quickly. You can do it cheap. You can do it right. – Pick any two.
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Peteff
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| posted on 22/6/11 at 09:11 AM |
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Put a countersunk set screw in the hole and a few big washers on the other side followed by some smaller washers to grip to. Tighten a nut on the back
side and the head should countersink the hole.
yours, Pete
I went into the RSPCA office the other day. It was so small you could hardly swing a cat in there.
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2cv
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| posted on 22/6/11 at 12:47 PM |
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Good advice from the above. For a small hole a Joddler would not work but a simple press tool certainly would. If you have a number of holes all the
same to do, it's might be worth making up as tool. Try to ensure that the aluminium is clamped top and bottom so that the panel will not be
damaged.
The attached pictures show a tool that I made up to for a base for headlights.
[img]
 
Press tool
[/img]
[img]
 
Press tool
[/img]
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jacko
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| posted on 25/6/11 at 08:21 PM |
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I may be wrong but i think he want's a inspection hatch type hole say like over the foot peddles say 200mm x 300mm and a flat panel fitting in
the rebate
Am i right Ceebmoj ?
Jacko
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John Bonnett
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| posted on 25/6/11 at 09:08 PM |
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Something like this access hatch? (adjacent to the rear suspension clevises)
[img]
 
Access hatch
[/img]
[Edited on 25/6/11 by John Bonnett]
[Edited on 25/6/11 by John Bonnett]
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John Bonnett
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| posted on 5/7/11 at 09:20 AM |
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Just a few more details of the tool I used. It's called a Rolastep and available from LB Restorations. Link:
http://www.lb-restoration.co.uk/cgi-bin/store/commerce.cgi?cart_id=1261895706.1342&product=RESTORATION&pid=377
It is easy to put a stepped flange round a radius but I'm not sure if the flange would be wide enough for a Dzus fixing. I used M5 rivnuts.
Oh, I've just read that it can do a 12mm or 17mm flange so this should be ideal.
A couple of pics below.
John
[img]
 
Description
[/img]
[img]
 
Description
[/img]
[Edited on 5/7/11 by John Bonnett]
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ceebmoj
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| posted on 5/7/11 at 04:17 PM |
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quote:
Originally posted by jacko
I may be wrong but i think he want's a inspection hatch type hole say like over the foot peddles say 200mm x 300mm and a flat panel fitting in
the rebate
Am i right Ceebmoj ?
Jacko
yep thats what i'm trying to do.
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locogeoff
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| posted on 6/7/11 at 12:36 PM |
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You want a rolastep joggler, kindof expensive for a one off job though.
Regards
Geoff
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John Bonnett
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| posted on 6/7/11 at 01:06 PM |
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quote:
Originally posted by locogeoff
You want a rolastep joggler, kindof expensive for a one off job though.
Regards
Geoff
Two posts up, keep up at the back 
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MikeRJ
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| posted on 6/7/11 at 02:20 PM |
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You should be able to achieve this using simple male/female wooden forms that you can clamp the sheet between. For making these a wood router would
be a useful tool to own, but not completely necessary as you can build up forms from multiple thin sheets of material.
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2cv
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| posted on 6/7/11 at 03:42 PM |
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quote:
Originally posted by MikeRJ
You should be able to achieve this using simple male/female wooden forms that you can clamp the sheet between. For making these a wood router would
be a useful tool to own, but not completely necessary as you can build up forms from multiple thin sheets of material.
Ah Mike, a man after my own heart. Very simple, no expensive tools needed, clamp it up an tap it down and the beauty of this method is that you can
make the step whatever width you need.
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