Metal bracket Fabrication...

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Although not specificity cruiser related I thought I’d share some of my previous knowledge and current findings. Sooner or later we’ll all need to make brackets to mount things on our Landcruisers.


I’ve always heard that aluminum work hardens...
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This small bracket was the first (prototype) mounting bracket... to mount a RYOBI fuel tank on my Stihl line trimmer. When I bent it up I knew that bending it past 90* was a compromise.
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It lasted about 15-20 minutes. The small engine has almost no vibrations... but after using about 1/2 of a tank I discovered it broken at some point. Had it been a intercooler mount, turbo bracket, light mount, gauge mount, or 100 other things... the results could have more serious. In this case there were no problems as a result.

Here’s the new and improved version beside it
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Note the angle is still past 90*, but only half of what the previous angle was and a wider radius.

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For this application I used 1/16” aluminum. For a Cruiser I’d recommend a minimum 1/8”. Heat also helps to reduce internal stresses from bending metal.

Here’s the project:

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‘80s Japanese made Stihl Comercial grade trimmer/bush cutter. Compared to my decent, newer Stihl line trimmer, it’s like stepping up to gas from electric (all over again). It’s line will even go through stalks, blackberry vines (even 1” thick) and whatever else is in its path.
 
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There's also something to the particular alloy that makes it more or less suitable for bending.

6061 likes to crack when bent, 5052 is a bit softer I guess.
Not that you ever really know what the scraps in the bin are.

Bigger radius will definitely help tho.

There's lower numbers too apparently.

I looked into it a bit when I was thinking of doing my bed sides out of aluminum, but I'd have had to pay a shop with a proper brake for it all and I wanted to do it myself.
 
Very true, I don’t recall the grade. I had a ton of strips cut by a fab shop. They were bought to make 90* bends in... I never had any issues with them before, even with sharp 90-180* bends. I’m sure frequency of vibrations also plays a factor. 10,000 rpm from a 2-stroke is much higher you’re going to see on a Landcruiser
 
There is a process called Annealing where you heat and let it cool on its own. Having owned Land Rovers as well and doing body work on aluminum I learned the process and it can be done. Having said that steel is much more flexible and holds up better too vibration. I have yet to master welding aluminum, it's like welding butter as it melts fast.
 
With the right grade of aluminum, if you heat it hot enough to char a wood stick, and then let it cool, there’s a window to work with it before it returns to the original state.
 
There is a process called Annealing where you heat and let it cool on its own. Having owned Land Rovers as well and doing body work on aluminum I learned the process and it can be done. Having said that steel is much more flexible and holds up better too vibration. I have yet to master welding aluminum, it's like welding butter as it melts fast.
Here’s a project for you…
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Seal the doors and windows with duct tape.
install schrader valve - inflate! That’ll pop right out!
 
Seal the doors and windows with duct tape.
install schrader valve - inflate! That’ll pop right out!
It’s a shame… it I had a thousand hours to spare, I’m sure it could be buffed out.
 
Side note for bending aluminium. . 5052 is used for bending .. 6061 structural. . Difference is how they are treated when made.. 6061 age hardens..
As for bending .. bend against the grain of the aluminium. . If your bend is with the grain of the aluminum it will Crack. .. this is also falls into welding aluminium .. if your welding a groove weld .. joining two plates together. . You weld against the grain.. ..
 
Side note for bending aluminium. . 5052 is used for bending .. 6061 structural. . Difference is how they are treated when made.. 6061 age hardens..
As for bending .. bend against the grain of the aluminium. . If your bend is with the grain of the aluminum it will Crack. .. this is also falls into welding aluminium .. if your welding a groove weld .. joining two plates together. . You weld against the grain.. ..
I’d not realized the grain makes such a difference. Makes sense though… even plastics have grain, and it impacts moulding.
 

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