I want to remake my 911 out of aluminum. How do I do it?

[Wrecked944]

Well, not the entire car...but I want to try to form some of the simpler parts from aluminum sheet. So can anyone tell me what kind of alloys and thicknesses of sheet I should use and where the best place is to buy it? I've looked up McMaster-Carr and they appear to only sell small sheets. And I assume I might need some large sheets. I figure I'll try to build some hammerforms and then go to town. Any ideas?

[klaucke]

I have some sheet aluminum if you need some Janus. Not sure exactly what you want, but I made replacement panels out of sheetmetal before (although steel). I have some tools, etc.

Now that I recall, I did make my driver side floorboard out of some aluminum sheet.

[Early_S_Man]

Janus,

You should be able to get some large pieces from a local shop that does fabrication or repairs on aluminum trailers. I have gotten 0.060" aluminum from a local trailer fabricator.

[Joeaksa]

Aircraft supply shops have all the sheet you will ever need, and in any sizes you can afford. Get a mallet and start forming it. Should not take long to realize that its hard work and very specialized at that...

[dean]

Janus, You are such a knucklehead. Maybe that is why I like you.

Mill Metals in Manchester NH will supply you with all the metal you need. They will deliver but have a $150 min. That is easy to do with Alu. But you can go pick up smaller amounts.

3003 is a soft workable alloy.

There is a really good book on metal fab.

Metal Fabricator's handbook by Ron and Sue Fournier.

[A Quiet Boom]

I gotta warn ya, metal forming is a lost art. I've been practicing for years making little things an I know I couldn't do a fender yet. To do it right you're gonna need a bunch of tools besides a hammer. English wheel, shear, bender, roll former, special hammers and dollies, and a LOT of patience. One of these days I'm gonna get a wheel and shear for myself but I can't seem to stop collecting machine tools

[PPilot]

Experimental Aircraft Assn. (EAA) Oshkosh, Wi. has how-to books, as well as runs hands-on courses at some of their larger fly-ins at Oshkosh and Sun and Fun in Lakeland, Fl. Not a skill to enter lightly!!! Truly an art form.......Good luck!!

[Wrecked944]

Thanks for the great replies! I totally grasp that forming aluminum is difficult. That's why I want to do it! But have no fear. I am planning to start out replicating a gas door...simple oval with no compound curves. Then maybe a nose panel for my 944 (one bend, no compound curves). Baby steps. And yes, Dean, I am a knucklehead. But let's just say there is a guy I know who weld's his own intercoolers and makes his own steering wheels and so pretty soon I start thinking anything is possible.

Oh yeah, I already have the Fournier book. And I have one of his videos. Excellent stuff.

Any holy cow, thanks for the advice on trailer repair places and aircraft suppliers. I had not even considerd those options. So I popped open my Wick's Aircraft Supply catalog and VOILA! Not only did they have aluminum sheeting available but also metal fabricating tools and instructional videos. Brilliant!

[A Quiet Boom]

Check your area for a metal supplier. I do a lot of machine work and get my AL and SS from one company and my steel from another. I even got a sheet of AL polished diamond plate that I plan to use for a "bed liner" in my Ranger.

[dd74]

Originally posted by A Quiet Boom
I gotta warn ya, metal forming is a lost art.

Interesting, specifically because I see increasing numbers of cars with aluminum hoods and trunks - the Subie WRX STi and Mitsu EVO, specifically. I'm sure there are others out there -- Ferrari, maybe, who have aluminum hoods and other body panels.

Wasn't the DeLorean made of aluminum?

Personally, I like aluminum in everything except a bicycle frame, which is where al and man cannot co-exist, at least for no more than two hours - hint: aluminum bike frames will tear your body to ribbons on less than smooth roads.

But as for body parts, sure, I'd trade in old steel or fiberglass parts for aluminum, particularly as aluminum is much more durable than fiberglass.

My question would be what gauge and weight is the typical 911 hood, and what would that weight be in aluminum? Also, would the hood flex at speed (which I doubt it would).

Janus, I admire your tenacity and agressive thinking. It'll be cool if you pull this idea off.

[Joeaksa]

Janus,

I know a guy who has a english wheel and makes his own aircraft nosebowls by hand out of aluminum sheeting. He is an artist and they just are not many people like that these days.

Spend some time at it and enjoy! Its an art working with metals...

[david.avery]

Originally posted by dd74
Wasn't the DeLorean made of aluminum?

Stainless steel, no coating, thus all the thumbprints

[A Quiet Boom]

dd74,

By metal forming I was refering specifically to handforming and not just AL but steel and other metals as well. The cars you listed all have stamped parts done by machine.

The problem with some AL alloys is that they can work harden and crack. I forget which ones are best for forming so check with a supplier.

I've been toying with doing an AL hood and deck lid for my '73, possibly even door skins if I can find a good way to insulate the steel parts from galvanic corrosion.

[89turbocabmike]

Janus, in case you haven't come across this already, this is an excellent site/forum: www.metalmeet.com

[GeorgeK]

Janus,
Dibs on the gas door.

[Porsche_monkey]

Originally posted by dd74
Interesting, specifically because I see increasing numbers of cars with aluminum hoods and trunks - the Subie WRX STi and Mitsu EVO, specifically. I'm sure there are others out there -- Ferrari, maybe, who have aluminum hoods and other body panels.

Wasn't the DeLorean made of aluminum?

Personally, I like aluminum in everything except a bicycle frame, which is where al and man cannot co-exist, at least for no more than two hours - hint: aluminum bike frames will tear your body to ribbons on less than smooth roads.

But as for body parts, sure, I'd trade in old steel or fiberglass parts for aluminum, particularly as aluminum is much more durable than fiberglass.

My question would be what gauge and weight is the typical 911 hood, and what would that weight be in aluminum? Also, would the hood flex at speed (which I doubt it would).

Janus, I admire your tenacity and agressive thinking. It'll be cool if you pull this idea off.

Lots of cars use aluminum for the hood, they are strengthened by the under side stiffeners that are glued and hemmed (rolled over edges) to the top. No welding, no flexing.

Austin Healeys had aluminum body panels, did not co-exist well with salt. I don't know of any modern cars with Aluminum fenders.

[david.avery]

Originally posted by PBH
Austin Healeys had aluminum body panels, did not co-exist well with salt. I don't know of any modern cars with Aluminum fenders.

Audi RS4 fenders are aluminum, as are the fenders on the A6. My subie has an aluminum hood and lid as well.

Also, there are some coach builders that are building some 550 replicas out of aluminum, using some varied techniques. Check the spyderclub site in my sig, maybe they can help.

[GeorgeK]

Porsche 928 has aluminum fenders. 997 has aluminum front lid. 959 and 964 Turbo Lightweight had aluminum doors. My own '76 Carrera has aluminum front and rear lids...

[deanp]

Janus -

If you are serious, there's a guy in Wheelwright (by Barre) - would be about 1/2hr or 45min. from you house. His name is Fay Butler, Jesse James (you know - West coast Choppers) learned his metal craft, cutting hammering, english wheel, shaping etc. from him. He is supposed to be one of the best in the world. I know there is one brand of cars that were handbuilt, I think in the UK that Fay became known as THE person to completely restore these to concour condition.

I am not sure how open he is to visitors, or how accessible his time is, but if you are serious I would recommend trying to visit. He also has at least one book out there.

I've never met him, but have heard that he truly is a master craftsman.

FayButler
Fab/Metal Shaping
51 Cleveland Rd
Wheelwright, MA 01094
413-477-6449

[deanp]

Janus -

Even better - Fay's website - not sure how current it is but he does (or did) SEMINARS!!!

Fay Butler

Since you are 'in between' work gigs you should find out what goes on!