Talk Morgan Forums Morgan Sports Cars Classic Morgans (pre-CX) Tooltray - how to bend aluminum?

. Thinking of just using the underneath of the original tray as a moulding for a layer of fiber glass and plenty of resin, should work.

For some reason I don't gel with fibreglass.

Hello Dave,

that‘s the point - why? Is it a forgotten craftsmanship?

René

I've just completed the fibreglassing of the cabin top of my boatbuild. I did the hull a couple of years ago.
It's time consuming, messy, you have to be very organized material wise because of the limited time you have to work with the resin and it's a significant health hazard. Exposure to the resin and cloth/matting can cause serious health damage!!
It's been my least favourite part of the build, closely followed by the painting using a two pack system.

That said, it can produce good results but I made my tool tray from plywood.

And by the way Dave, your subtle humour didn't go unnoticed

I'm in the wooden tool tray camp, not only because compared to the other options it's quick and easy requiring no special tools or skills, but also because as it integrates with the body frame, wood seems to me to be the most appropriate solution.

My first tray was wood and it does the job.

My second tray was based on a single piece of aluminium in a gentle curve, with sides and diff cover added. That was a tough challenge.

So my third tray was made of sections. One each side with a centre section. This method works well.

Wood also seems to be a better sound dampener.

As SimonH says the grade of Ali is key. There are different grades for different end use, from simple noncritical use to more exotic alloys, particularly the aerospace grades. Some are age hardening due to deliberate alloying composition, as with all metals, not just Ali.
Brings back memories of my days as a Metallurgist.

Some days ago, in my area a lot of good days out in the MOG.

Today I start a new try.

At first: heating wasn‘t my thing. German fear. I‘m afraid about overheating.

So the simple way: brute. No secco.

To do it Brut there are different ways. At first I start with a piece of wood 20mm thick and 150 to 300mm with a 500gramm hammer.
Works. But not in my sence.

After some time of frustrating beats I change over to a massive blog of wood 50x50mm and 300mm long and a 1000gramm hammer.That was a massive step forward. Works.

So with this knowledge I fished the first bended sheet.

Next step - you will see.

René

I guess I'm fortunate in knowing a local old school guy that rebuilds Classics. He works on a shoe string and buys up old machinery as required. One such purchase was an electric sheet press. It had no difficulty putting sharp bends in 3mm sheet steel for a small job on my Land Rover. It wouldn't even notice 2mm ally.