Making ally door frames.

Window frames btw...........lol.

I picked up a few lengths of killer extruded ally lip channel that I would like to try and fab into window frames. Any ideas on how to form this stuff, or should I take the whole lot to a welder and have them do it?

Here's good example of an end product -

http://www.fibersteel.com/OldSite/SlideWindows.html

I'd make a cardboard template for each side then cut piece of 3/4" plywood for a jig or buck. Product could then be heated and bent to shape. I'd tap threads to connect to bottom pieces so you can insert the plexiglass.

"I'd make a cardboard template for each side then"

We use cardboard templates frequently - it's called CAD.

Cardboard Aided Design - ;-}

Mike - I tried using AutoCad to design vacation house for on Chesapeake Bay - first hurdle was "orthogonal lines" and how wide to make the walls (like do you acct for drywall, sheathing, siding and 2x4" aren't 2x4"?) and was down hill from there! Ended up using cardboard and hot glue gun. Problem now is I can't find 34'x34' cardboard and a huge hot glue gun! CAD --- good one!

dear Wolfgang,

hire me. I am a broke architect and speedster owner. not sure if im broke because i am an architect or because i own a speedster. either way, ill draft up a house for you.

Paul

It's because you are an architect. There is a lot of evidence.

Wolfgang'
Where did you get the aluminum extrusion ?

Gary ,
If what you got is a dual-web channel extrusion , you'll prob need to notch the webs on the gentle curves ,and cut them clean off for the sharp bends. still will be plenty web left to keep the plexi sliders in their tracks .

Most extrusions are hardened , so look here for annealing techniques:

http://www.practicalmachinist.com/vb/fabrication-cnc-laser-waterjet-plasma-welding-fab/annealing-aluminum-sheet-help-199317/

Wolfgang & Dave

Thanks a million for the info and shame to the rest of you for going off topic.....lol.....kidding.

It's a basic single channel that I've got btw.

The ally that I got is a basic 3 sided profile that is a tad bigger than the free plexi sheets that I got for windows. So it'll allow for a rubber gasket of sorts. For a first try I'm not going after anything fancy, Just a window that can slot into place to keep the worst of the worst out. I may look into a sliding option if I don't mess this one up too bad.

I was also thinking of building a 6mm ply plug and then playing with some heat a bit.......Stay tuned, I may have something to show on monday. I may also have a blob of goo to show as well.

lol.

Gary,
A little thread drift! Any updates on your 4 cam engine build? Pictures!

What Allan said X 10!

CharlieNorton - the link I posted was to the Fibersteel site -- they aren't mine. FS seems to have clever ideas but a lot of them are one off items and don't make production. I'm thinking a boat building place would have usable stuff for runabout windshields.

Well blow me over.............it's going to work. I took a scrap section of lip channel and played with it a bit and low and behold after heating it up, I put it over the ply blank and it bent so easily.

I have some adjustments to make before I go full on this like trimming my window plug so that it fits a bit tighter in the window opening once the soft top, this is more than likely going to involve cutting it down a bit.

As well as seeing if I can get the whole top section done in 1 peice by notching the 90 degree bend where it meets the front window, but hey it's very promising. But I'm so chuffed with the results so far.

I used a heatgun to heat the ally up by the way. Takes a tad longer, but allows me to play with it a bit more and also not to give it too much heat. I should have a full prototype up and fitted by the weekend.

As for the Engine queries, it's still being built, no new pics I'm afraid, my engine builder has a few other projects of his own taking up his minimal time, so I'm just gonna have to be patient. As soon as I have something, then I'll post it.

- G

Please describe the "lip channel" or an end picture (x-section) + dimensional info of channel (thk). Very nice job from what I can see from your provided images!

I'll snap some pictures tonight of the profile, it's basically a U.

1cm sides and about 8mm middle section.

I was honestly surprised how easy it bent after being heated. I really didn't give it full steam as well. But having the plywood plug made all the diffs. Just some trimming and then I can go at it again with the other sections. I'm going to change things a tad.

Picture worth a 1000 words! Now to incorporate some opening vent - even like DeLorean had would be great.

http://www.lockergnome.com/theoracle/files/2007/08/delorean_brochure3_81-thumb.jpg

Gary-Got any pictures of your efforts/progress?
Thanks, Scott

Slater.......there are 2 pics that I posted that shows the bent part, but alas, I'll only have more over the weekend. Working late hours really screws with my speedster time....lol..

I dated Ally once :~)