Author Topic: is your car body skinned in aluminium? (Read 372 times)

Tinworm · « **on:** 02 Apr 22, 10:59 pm »

I have been astonished by the quality of finish on lots of people's cyclekarts and been amazed to note that some really terrific results can be achieved without any aluminium sheet, so can I ask, have you finished your bodywork in aluminium or ply - or what?

If aluminium, how thick was it and where's the best source? I think I will get mine cut lengthways - as my kart, luckily, has a consistent height.

Can we get anything thinner than 0.9mm? (It doesn't need to be strong in my case, as it will be over a decent frame).

If not aluminium, what? And how did you get a great finish without it?

jim · « **Reply #1 on:** 03 Apr 22, 06:17 am »

I used 1.2mm aluminium and got it from ASC as I have an account but they are usually quite expensive.

StefanN · « **Reply #2 on:** 03 Apr 22, 07:26 am »

The Bugatti is skinned in ply, flexi-ply and fibreglass. Not sure it’s got the great finish you’re talking about but where it’s got a better finish, it’s because I filled the grain of the wood with high build primer and sanding.

I got a sheet of aluminium from a small local company that makes bespoke boxes and enclosures - I just phoned them up, explained I was after some ali for a hobby and they sold it on with a small mark up.

Tinworm · « **Reply #3 on:** 03 Apr 22, 09:58 am »

Quote from: StefanN on 03 Apr 22, 07:26 am

The Bugatti is skinned in ply, flexi-ply and fibreglass. Not sure it’s got the great finish you’re talking about .

Yours was the one I wanted to see most and when I did I thought it was terrific, and a great example of what can be done without tricky curves.

Tinworm · « **Reply #4 on:** 03 Apr 22, 09:59 am »

Quote from: jim on 03 Apr 22, 06:17 am

I used 1.2mm aluminium and got it from ASC as I have an account but they are usually quite expensive.

now I am wondering if 0.9 is too flimsy, but as I say, it isn't structural.

Mark Underdown · « **Reply #5 on:** 03 Apr 22, 10:09 am »

I used 1mm Aluminium on mine. I think much thinner and it would be difficult to work with,

The state you buy it in has a lot to do with how easy it is to form, it’s worth looking for annealed.

Aalco supply by the sheet and are one of the largest suppliers of Ali in the country.

Tinworm · « **Reply #6 on:** 03 Apr 22, 10:19 am »

Quote from: Mark Under on 03 Apr 22, 10:09 am

I used 1mm Aluminium on mine. I think much thinner and it would be difficult to work with,

The state you buy it in has a lot to do with how easy it is to form, it’s worth looking for annealed.

Aalco supply by the sheet and are one of the largest suppliers of Ali in the country.

Very useful points! Right, looking for annealed, definitely, and take your point about workability. Thanks

Seven racer · « **Reply #7 on:** 03 Apr 22, 10:45 am »

For flat panels, and ones with single curvature I'm using second hand Dibond, a sign making material. It's a composite of two thin aluminium layers which sandwich a plastic core. I have 2mm and 3mm, and if you can find it second hand, it's cheap.

I paid about £35 for two 8 x 4 sheets, but I did have to drive 70 miles to Nottingham to collect them.

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The only problem I have found with it so far is the inability to put louvres in it,

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so I am going to have to resort to some sort of fakery.

Peter

synthpunk · « **Reply #8 on:** 03 Apr 22, 11:35 am »

Coming from a model steam boat background, Ive been toying with the idea of doing some of mine (the bonnet) in tinplate. In the boat club we have various 5 foot long, nearly 100 year old steamers made of such exotica as bully beef tins and baby formula tins. Luckily I drink industrial amounts of coffee at work, so I’ve been saving the large catering sizes of coffee cans we get that in.

We shall see….

David F-R · « **Reply #9 on:** 04 Apr 22, 08:38 am »

I notice in the US, they seem to use a lot of 1.5mm 'aluminum' for their bodies.
Is that because it's easier to get hold of, or needed for the structural strength?

RhysN · « **Reply #10 on:** 04 Apr 22, 09:50 am »

Having gone through this exercise with my full size Morgan, under advice from the Morgan club I have used 1.2 mm 1000 series alloy. That is a modern version of "soft". I also acquired some 1.5 in a 5000 series, it's unworkable unless you anneal it.
If I were doing a cyclekart with any framing at all, I would use 1.2.

David F-R · « **Reply #11 on:** 04 Apr 22, 10:01 am »

That's helpful. Thanks Rhys.

Tinworm · « **Reply #12 on:** 04 Apr 22, 02:53 pm »

Thanks Everyone, that was really helpful.

TheGiantTribble · « **Reply #13 on:** 05 Apr 22, 12:07 pm »

Sorry late to the party on this one...
Mines fibreglass over variously plywood, polystyrene, and the odd bit of timber.
Also defo not one of the nicer finish's but a few hours rubbing down and then
re painting would fix most of it's problems in that dept.

Chris L · « **Reply #14 on:** 05 Apr 22, 01:46 pm »

On this topic of body finish . I quite like the less than perfect finish . Some of my Aluminium used was at least 25 years old caravan skinning ally, complete with imperfections . Had it stored in back of garage all that time.

Plus when i sprayed it with aerosol can in mid winter 2020/21 , it went quite patchy. Due to hot n cold areas .

I think it's called Patina

Probably some of the vehicles that we chose as inspirations , didn't have a great finish in their day.

Chris L

Author Topic: is your car body skinned in aluminium? (Read 372 times)

Tinworm

is your car body skinned in aluminium?

jim

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StefanN

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Tinworm

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Tinworm

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Mark Underdown

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Tinworm

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Seven racer

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synthpunk

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David F-R

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RhysN

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David F-R

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Tinworm

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TheGiantTribble

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Chris L

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