Morning all

I'm going to try and fabricate a couple of small aluminium covers for various purposes.

I haven't a clue about forming aluminium apart from basic brackets with 90 degree bends in etc.

The covers will have varying angle curves in from 180deg to nice gradual curves.

I haven't any specialist tools etc, what thickness ali would be best for easy forming by hand without fighting it whilst being rigid enough to keep its shape well once formed.

Any assistance much appreciated.

Cheers
Nigel

i have use 0.9 mm for various panels and covers, seems rigid enough for me and fairly easily formed

You could laminate several layers of tinfoil together, with slow setting epoxy glue, that way you could form it with your hands into any shape you wanted.

Oh what genius must be worth a patent...

Did you know that the moon Lander cabin was only about 5 layers of tin foil thick, Buzz Aldrin said that he could have easily stuck a pen through it

Anyway 0.5mm think aluminium forms very easily using either a plastic (best) or rubber hammer, don't use a steel one as they mark the surface badly. A gently hammering the sheet into bag of sand is one of the best ways to make nice curves

quote:

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Originally posted by Mr Whippy
You could laminate several layers of tinfoil together, with slow setting epoxy glue, that way you could form it with your hands into any shape you wanted.

Oh what genius must be worth a patent...

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quote:

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Originally posted by Paul TigerB6

quote:

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Originally posted by Mr Whippy
You could laminate several layers of tinfoil together, with slow setting epoxy glue, that way you could form it with your hands into any shape you wanted.

Oh what genius must be worth a patent...

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Get yourself down to the next marathon Mr Whippy and collect up all the used space blankets. You can then use these to panel your next car using your method as a trial!!

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