Before I just keep making attempts, any advice or tricks you found helpful in making the corner conical gusset for the baffles (outside corner of inlet)? I have a good paper shape, but so far my attempts at turning that into aluminum have been pretty sub par. Bending/rolling became easier once I oversized the initial piece, but I still can't seem to get a part that lays nicely.
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Baffle Conical Gusset
- Thread starter skelrad
- Start date
print out the template on paper, stick to the aluminum and bend according the several lines using either a large vice (or vise if that better suits your ideas), or a bending brake. Easy little steps in several passes, increasing the bend until the given shape is reached.
Recently did some using 2024-T3 with no issue.
Recently did some using 2024-T3 with no issue.
Try finding a larger diameter of scrap PVC pipe or similar. Folding mine over that worked fairly well.
Not sure if this is what your looking for??..the lower corners to match the inlet shape? I made all my own baffles from scratch. here is how I addressed the corner. Very simple, same .032" 2024-T3. Just a riveted in separate piece. I made an entire baffle mock-up that fit the engine from Budlight beer boxes, each piece taped together, and after final fit, I untaped and transfered to aluminum..wish I had kept that "beer baffle" for talking points.
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Mike means 3003 aluminum. Use that stuff and you'll be pleased I think. 2024-t3 is not dead soft and springs back when its formed then work hardens when formed. When I form 2024, I want to find the right radius to form the aluminum around in one try. I will cut a 1 inch wide scrap and form it over a radius that is a bit smaller than I need then see how I did. This gives me an idea of what I will end up with on the real piece when i form over the tube. I only test it once then throw it out becuase it's now slightly work hardened.
I didn't have any "soft" aluminum sheet, so just kept at it with what I had. It took more attempts than I'd care to admit, but I finally have something acceptable. As always, after getting it done, I can see how I'd do it differently next time, but that's part of the game.
With stuff like this, I find it very helpful to mark the part on a piece of aluminum, but initially cut the aluminum a couple of inches outside the perimeter of the marked lines and bend, crease, fold, mutilate, using the extra size for leverage. Then once it is bent, cut to final size.
