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Aluminum fabrication

  • Thread starter Thread starter ValorSolo
  • Start date Start date
V

ValorSolo

Guest
I scrounged a partial sheet of aluminum from my brother.
It's about 18" x 48". He has a full 4' x 8' sheet if (when) I need more.
Anyways, I started fabbing some brackets for my gs750.
I don't have any pictures yet, but so far I have the tail light/license plate bracket cut.
I actually had one cut yesterday and polished real nice, but screwed it up trying to bend it.
So today I will attempt to make a folding tool. Then I can fold the bracket and get some pictures on here.

I will try to get a rear brake reservoir cover, battery box and headlight brackets out of the remaining material.
It's too bad he doesn't have some stainless steel, I need to build some brackets for my SS grab bar.
I don't suppose I can weld aluminum to stainless without corrosive results.

I started this thread to come back to and post some pictures, so I'll update when I can.
 
I didn't get home in time to build a folder, but I did pick up a 10" c-clamp with a 3" jaw.
With it I was able to bend the bracket just the way I needed it.
Here's some pictures of the material I'm using and the bracket.
Zi6_5029.jpg

Zi6_5028.jpg

Zi6_5030.jpg


I'm not quite done with it yet. I managed to scar it up while bending it.
I'll have to sand and polish again. And I want to round the corners a bit.
I still have to drill the holes for the tail light and the tag grommets.

More pictures to come after I get it mounted.
 
I finally mounted the bracket and light to the fender. Still have some more work to do to it.
I used the tag light bolts in the two holes above the tag slots to attach the bracket to the fender.
This way, I don't have wires showing and it should light up the tag just as well.
Zi6_5032.jpg

Zi6_5034.jpg

Zi6_5035.jpg
 
Looks very good but may I make a suggestion? The shelf part that the tail light sits on looks too square for the curves of the fender and the light itself. I think if you narrowed it down somewhat and rounded off the back edge ( i.e. make semicircular) it would integrate the lamp more.

Nice little project, well done and thanks for sharing.

cheers,
spyug

On looking at it again, perhaps you could shape that back edge like the "diamond" like profile of the base of the lamp. I actually think that would look the best.
 
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Nice one! You've done well :)

I did some alu. fabrication on my 450 for the fork brace/front guard mount, battery box cover, Acewell speed sensor bracket, and the little dash to hold the gear position indicator and voltage monitor beside the Acewell gauge.

Like yourself I just used what I had available; bench vice and various C clamps. Seems to have worked well for me too.

I didn't polish mine up though, I either went the brushed look (fork brace/guard mount) or painted satin black.

How thick is that by the way? I've used one that's about 1mm for the dash, speedo sensor, and battery box cover, and 2.5mm for the brace/guard mount and the bottom part of the dash. That 2.5mm stuff sure is hard to bend!
 
Nice work there....thanks for sharing
You did fit some rubber grommets between the fender and the bracket, right?
 
Very nicely done, I bet you could sell these on the forum and on ebay, just undersell the competition. Not just for Zuk owners either.:clap:

53622651.jpg
 
spyug said:
Looks very good but may I make a suggestion? The shelf part that the tail light sits on looks too square for the curves of the fender and the light itself. I think if you narrowed it down somewhat and rounded off the back edge ( i.e. make semicircular) it would integrate the lamp more.

Nice little project, well done and thanks for sharing.

cheers,
spyug

On looking at it again, perhaps you could shape that back edge like the "diamond" like profile of the base of the lamp. I actually think that would look the best.
Click to expand...
I was wanting to round it off a bit, but I"ll have to wait on my next trip to the hardware store to get some dremel stuff.
I already wore down all the bits I had on hand. The diamond idea sounds cool. I'll give it some thought.

pete said:
Nice one! You've done well :)

I did some alu. fabrication on my 450 for the fork brace/front guard mount, battery box cover, Acewell speed sensor bracket, and the little dash to hold the gear position indicator and voltage monitor beside the Acewell gauge.

Like yourself I just used what I had available; bench vice and various C clamps. Seems to have worked well for me too.

I didn't polish mine up though, I either went the brushed look (fork brace/guard mount) or painted satin black.

How thick is that by the way? I've used one that's about 1mm for the dash, speedo sensor, and battery box cover, and 2.5mm for the brace/guard mount and the bottom part of the dash. That 2.5mm stuff sure is hard to bend!
Click to expand...
I started working on a battery box this evening but haven't gotten much done yet.
I'm not exactly sure how thick it is, around 1/8" I guess. It's very hard to bend.
Flyboy said:
Nice work there....thanks for sharing
You did fit some rubber grommets between the fender and the bracket, right?
Click to expand...
Not yet, but I intend to. And a rubber gasket between the light and bracket. Just need to pick up some material.
old_skool said:
Very nicely done, I bet you could sell these on the forum and on ebay, just undersell the competition. Not just for Zuk owners either.:clap:

53622651.jpg
Click to expand...
Without the proper tools, mass producing would be too time consuming to be profitable.
A few for my friends may be something I would consider.
 
Harbor freight has two sizes of bench top metal breaks. Both fairly cheap. They're on my list of "needs" for the garage at some point.
 
This reminds me. Maybe I will just make my side covers out of some metal instead of plastic like I was working on. Plastic works, it's just a PITA compared to metal. Any kind of metal really. I will probably just use some thin diamond plate. A scrap metal place up by me usually has a bunch. it's $2 a lb for alum of any sort. Not too shabby.
 
This reminds me. Maybe I will just make my side covers out of some metal instead of plastic like I was working on. Plastic works, it's just a PITA compared to metal. Any kind of metal really. I will probably just use some thin diamond plate. A scrap metal place up by me usually has a bunch. it's $2 a lb for alum of any sort. Not too shabby.
Click to expand...

You mean something like this......
IMG_6432.jpg
 
Flyboy said:
You mean something like this......
IMG_6432.jpg
Click to expand...

Ahh a Benelli Sei cafe conversion. Gorgeous. The next cafe project I do will look largely similar. Even down to the stacked pipes (though 4 into 4 instead of 6) if I can pull it off. Oddly, if you look at a stock Sei, it looks very GS like in cosmetic detail.
That bike is gorgeous. Horribly underpowered, but an inline 6 sounds like the balls, even if it only puts out 60 HP
 
TCK, I am with you on that one, speed be damned, there is nothing to raise the goose bumps and make you feel like you have ice water flowing through your veins like a six at full chat.
Had a Z1300 with a Kerker 6 into 1 many moons ago, thing was a heap, but my God, the thing didn't half sound glorious at full tilt.
 
I made a folder for fabrication. It works great only on bends 1" or more from the edge.
I had a couple of bends that I wanted to make at 1/2", but wasn't able to do it.
It's due to the large gap at the pivot point. The gap is about 1/2", ideally it should be no more than 1/8".
When I find the right hinge to achieve a smaller gap and maintain strength, I'll make a new folder.

Zi6_5038.jpg

Zi6_5039.jpg


Here's the battery box I'm working on. I have it setting in place just to test the fit.
It's actually in two pieces and needs to be welded together and then polished.
I'm not sure how polished I want it yet. I may just sand it down and go with a brushed look.

Zi6_5036.jpg

Zi6_5037.jpg
 
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Flyboy said:
You mean something like this......
IMG_6432.jpg
Click to expand...

Hahaha a little more simple than that. I probably won't paint them, and if I do, it will just be black. I like your metal break. I will take pics of mine when I get back up to it. And if you dont mind a little more hijacking, I will post up what I'm doing.
 
Good work on the tool! That should help a great deal.

All of mine has been messing with C clamps and the bench vise, and something like that would've made it so much easier, but I just don't have the room for it I think... but I may investigate further if I end up doing more.

Right now I need to bend some solid 10mm steel rod for part of my carry rack, but I've determined I will need heat to do that successfully.
 
Using the vice and c-clamps is fine for small pieces, but it's hard to get a uniformed bend on longer stuff.
That's where the folder comes in. Just wish I had thinner hinges to get a smaller gap.

Right now, I'm trying to figure out which welding method I should use.
I've got some aluminum wire for my MIG welder, but I've never welded aluminum like that before.
I want to stick weld it but I'll have to go buy some 4043 rods, if I can find them.
I can't braise, so that's no option. I really need to learn how to braise.
 
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