Ive just junked my third rear panel!
Its starting to get to me and my pocket as its another sheet of ali' now required.
I keep splitting the the metal on the corners for some reason.

What the secret guys?

I think the secret is cheat!

Either dont roll the bottom edge around the lower round tube (wish id done this as mine looks like a dogs dinner) or use a slap hammer (also wish Id done this / known what one was before Id done the top edge!)

Geoff

A slap hammer one of these? http://www.chopperweb.info/forum/articles.php?action=viewarticle&am p;artid=98

?

Waiting with interest as I need to do this soon...

Dan

[Edited on 30/8/07 by Bluemoon]

Annealing with a carburising flame and soap ?

[Edited on 30/8/07 by zilspeed]

You could definitely try annealing it particularly around the troublesome areas such as where it rolls over the boot edge. Mine looks pretty crap here too.

I was taught to rub a bar of soap on one side of the Aluminium and heat the panel from the opposite side. When the soap residue begins to burn remove the heat and allow the panel to cool as slowly as possible.

Quite possible to localise this process for tricky bits etc...

Ha. Dont think i'll be making one. A very strange bit of kit.
I've been talking to a mate who built a Robin Hood and he says the trick is to only roll the metal over about 5mm. He bonded the bottom and rivited the top which was then covered with the boot cover
Annealing and carburising Sorry guys i have no engineering or mechanical training.

[Edited on 30/8/07 by scoop]

Seems a complicated way to make one.
Why not just put a 'chicane' of about an 1" in a piece of flat bar, narrow and ease the edges on the end you are going to hold and polish the other. Job done.

Now in confused and excited
I dont know what you mean mate but willing to learn

Normally the ally will only split if you stretch it to much.

If you are dressing the edge inwards you are trying to shrink the edge, so the problem should be that the edge is rippled.

Perhaps a pic would help.

Paul G

I was hoping you would come along
Ill take one in a little while but will have to email you if you dont mind. I cant upload pics on this forum for some reason thus no avatar or archive.

Hi Steve

Got your email with the pics.
You have U2U

Cheers
Paul G