[TheForge] Raising Aluminum Question

[Ries Niemi]

On Saturday, June 19, 2004, at 11:11 AM, Aaron Silver wrote:

> Hello-
>
> I'm getting my motorcycle on the road again after a 5 year hiatus. 
> When I parked it way back when I took off the side covers. Now 5 years 
> later I can't seem to find those pesky little things.
>
> While I can probably buy plastic (or fiberglass) panels for relatively 
> little, I decided to try and make a set out of aluminum. Since this is 
> my first attempt at anything remotely like this, I would appreciate 
> any helpful hints.
>
> My metalworking experience to date is mainly coal/gas forge and anvil 
> beating. I haven't tried cold forming aluminum (or any other metal 
> really), so I don't know if I need to anneal, or what.
>
> TIA
> Aaron
>


Aaron-
You can do your side covers in aluminum- but there is a learning curve, 
and you will need to make or buy some tools.
I would recommend first you buy the book "Metal Fabricators handbook" 
by Ron Fournier, HP books
This is a great book for all kinds of metalworking, but Ron is a master 
of handforming aluminum. He shows all the tools, several different 
processes, step by step. The big chain bookstores sometimes have it, or 
you can get it from Amazon. This is a great book that no metalworker of 
any kind should be without- I have taken a workshop with Ron, and the 
man is incredible. He builds cars from scratch, makes prototype parts 
for Ford and Chevy, and restores million dollar vintage cars so you 
cant tell they arent brand new.

You could probably do what you want with a leather shot bag and a 
wooden mallet- a pretty cheap combo.
It would be easier and better to then smooth it out with an english 
wheel, but you could do it with a homemade stake- like maybe the lid 
from an oxygen tank, and a metal bodymans hammer.
First you beat the rough shape in with the mallet and shot bag, then 
you planish the dents out with a smooth metal hammer and stake.

As far as material goes, 3003 is the easiest aluminum alloy to shape. 
But it is not available everywhere. Nowadays, there are a few guys who 
sell it mail order, in pieces small enough to ship UPS, and your side 
covers are probably small enough that you could get away with that. 
6061 is not a very good alloy to try this with, especially for a first 
project.

You do need to anneal any aluminum sheet before you try to form it.
Easiest way is to set your oxy/acetylene torch for pure acetylene, and 
put a layer of black soot on the aluminum. Then, with the biggest tip 
you have (a rosebud is good) you very very carefully just burn off the 
soot. Too much heat in any one spot, and you have a puddle of aluminum 
on your workbench. Then let it air cool, and the aluminum is soft. You 
may have to repeat a few times as you work it.

I would say, buy Rons book first, then go to the metalshapers web site, 
and ask who sells 3003, and buy a couple of sheets. Buy more than you 
need- you will screw up at first. Try to find someone who lives near 
you who has an english wheel, if you can. Most of the metalshapers are 
very friendly, and you can probably find one who would help you out.
Metalshapers are like blacksmiths- they are everywhere in the US, but 
kinda stealth like, so you dont know they are there.

www.metalshapers.org