Aluminium bodywork
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  1. #1
    Official RnS Addict 29stude's Avatar
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    Aluminium bodywork

    Anyone tell me what is a suitable grade and thickness of aluminium for bodywork? Fabricating bonnet, scoop etc

    Found Several different types suggested on internet. Hoping someone on here has a definitive answer.

    Thanks Gav

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    I'm Not Jed Clampett stueeee's Avatar
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    Not sure there is a definitive answer. I used 1050 sheet when I re-panelled the car in photo below. 1050 is pretty much pure aluminium. Normally comes as half hard, although you might want to anneal it if your doing work like the rivetted in bodywork "blister" in the pic below. Most of the bodywork on this car is 18 SWG (1.2mm), but 16 SWG (1.5mm) would be better if light weight isn't the most important thing.

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    Official RnS Addict WB54's Avatar
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    depends what you're doing when forming it. A thicker gauge is useful when stretching with a stretcher or English wheel, and when welding depending on your abilities. Thinner can be easier to shrink and easier to bead roll etc. Starting with half hard is the best bet but keep annealing it after each session forming.

    Where welding is concerned, i had a tough time welding formed panels where the edges had thinned, so I spent a lot of time blowing and fixing holes. If I were doing it again, I'd do a relatively cold butt weld on the inside first and fuse the outside with minimal /smaller rod , far less work in dressing the welds that way.

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    Official RnS Addict 29stude's Avatar
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    Thank you both for info. I’ve just been to local steel merchant and got some 1.5 mm sheet: conveniently their stock seems to be mostly 1050 grade.

    Stuuee your car looks spot on, is the blister for throttle pedal clearance?

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    I'm Not Jed Clampett stueeee's Avatar
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    Quote Originally Posted by 29stude View Post
    Thank you both for info. I’ve just been to local steel merchant and got some 1.5 mm sheet: conveniently their stock seems to be mostly 1050 grade.

    Stuuee your car looks spot on, is the blister for throttle pedal clearance?
    Yes, without that blister I would need to be wearing ballet pumps to be able to drive the car
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    Official RnS Addict WB54's Avatar
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    I put a blister in the side panel on my car when we realised the starter motor didn't fit inside the chassis


  10. #7
    Official RnS Addict 29stude's Avatar
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    Quote Originally Posted by WB54 View Post
    I put a blister in the side panel on my car when we realised the starter motor didn't fit inside the chassis

    Nice motor . I’m going need blister for same reason as stueee and because they look cool, in a sort of form following function way.

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