bending aluminum

[CRead01]

I am working on making aluminum tail lights for my camaro and they have a bend with a radius in them.

anyone have any tips on doing this? I am thinking about making them out of 1/2" aluminum and they will be about .750 wide on top and bottom. seems like it should be easy to bend but I want it to stay with the body line.

[Jim Nilsen]

When bending aluminum of any kind it is best to make sure it is as warm/hot as you can handle it. This makes it more malleable.

If you are doing tailights and only need that slight curve to match the panel you could start with a 3/4 in" piece and shape it by sanding with a block that is the same contours as the panel.

Aluminum of any kind doesn't like to be bent at all but some alloys are ok to bend 1 time. 6061-T6 doesn't like to be bent at all and is very resistant to it.

This is why the new billet tailights are are machined or cast.

I look forward to seeing what you are going to do !

[Bow Tie 67]

Bend across the grain or it will snap!!

[CRead01]

I drew it up on solidworks to see how i'll like it.

I'll try to post some pics up.

[CRead01]

this is what i'm trying to make.

they will be anodized black and then in the center I want to put one of larry's gas cap's anodized black also but recessed.

[Bow Tie 67]

I like it

[chengzi86]

The Universal Air Valve (not gate valve) is designed to permit the automatic escape of large quantities of air from a pipeline when the line is being filled, and to permit air to enter the pipeline when the line is being emptied.

[Jim Nilsen]

I drew it up on solidworks to see how i'll like it.

I'll try to post some pics up.

Very nice !

I was thinking you had a 1st gen but now I see that you have a 2nd gen 74 and up.

Remember that you can work aluminum just like wood except it is more time consuming and more dangerous. The tools that do the work can be the same but the tooling must be carbide to stand up.

If you can make them look like your rendering you will have people standing in line to have you make them. You might want to talk to someone about co-oping the prototype. I can bet that once a few others see what you are thinking you will have inquiring minds at your doorstep.

Have Fun

[CRead01]

I really am not looking to produce multiple parts.

just looking to make em for my car.

I am a tool and die apprentice and my boss lets me do some govt jobs on the side. I was planning on doing the milling on the machining center we have all flat then bending after.


I would be pretty cool though if someone did want to mass produce these. I think alot of people would like something like this since there is nothing on the market even close to this and even the oem ones are almost imposible to find.

[Jim Nilsen]

I keep thinking about the bending of the aluminum as the last thing and am just not sure if it will keep from showing the stress in the bend. If you were bending it so the curve was the other way you would more than likley not have a problem but when you have the radius on the visible side like you are bendin I have always had stress marks or cracks show up. Especially with material that thick and a lot less of a bend. that is rather thick to bend that much.

Try a piece before you go to all of the work of making the whole piece to be sure. That is an awful lot of work to do and not be happy with the look. Aluminum always seems to really hate being bent when it is over an 1/8th of an in. in thickness.

[seekins]

If you use a 5000 series aluminum your life will be much better. 6061 doesn't stretch much and will break, especially at a 90deg bend.
Are you going for aluminum for a brushed look or can it be made out of stainless?

if you want, i can look at the part for you. I have some great sheet metal guys that i work with and if it can be built, they can do it perfectly. PM me if your interested

[CRead01]

I thought about stainless but I had been planning on just anodizing the aluminum black.

I will check into the 5000 series aluminum.

That's kinda what I was wondering if there was one better than another or anything. The bend will only be about a 60 degree bend. not quite 90.

[MCC]

You can use 6061-T6 sheet it will bend ok just do not use 6061-T6511 or 6063-T52 Bar / Mini Plater it will break when you bend it !!!
6061-T6 sheet (4'x8') will bend ,we make motor plate out of it all the time with 45deg, bends 12" wide. 6061-T6 is not cheap $$$$$.

You need to use a 3003-H14 or 5052-H32 Aluminum Sheet it will work best for you and save you $$$$$...

http://www.mikescustomcars.com/proje...album=1&pic=13


Mike Riggs
Mike's Custom Cars
1-803-329-2835
www.mikescustomcars.com

[CRead01]

mike

How thick are your motor plates?

they look nice.

[MCC]

mike

How thick are your motor plates?

they look nice.

This motor plates are 1/4" thick by 12" wide 6061-T6 .

MCC has bent up to 1" thick by 26" wide 6061-T6 before.

[BMF Machine]

I just wanted to say good luck with your career choice! I am a 13 year journeyman, I love the machining trade!

[CRead01]

I just wanted to say good luck with your career choice! I am a 13 year journeyman, I love the machining trade!

Thanks

I have been in the trade for about 3 years now. I am done with my classes I just have to get my hours in.

I love machining also. I have made many of my own parts for my car and am always making more. I've got about 3 projects goin on for it right now. these tail lights a triangulated four link and i'm making a trim plate for the cowl on my hood.