Bending sheet aluminum

[500sks]

I want to make a roof for my UTV. What aluminum do I want so that I can bend it to make a rain gutter on the front and sloped edges. My idea is to get .10 aluminum diamond plate make a carboard template and bend and weld the sheeting to make a roof. By the way I don't have a break is there something I can make to bend the sheeting? If I can't make something to bend it, I think I could find a sheet metal shop somewhere to make the bends for me.
Any thoughts?
Thanks
Phil

 

[kevin47]

Yeah...Stay away from 6061...Doesn't care to be bent from my experience...Gets cracks or just plain breaks...But I'm usually using T6 (temper)...Anyone else with 6061 experience...?

 

[ZRX61]

3 or 5 series

 

[readhead]

6061-T6 can be bent across the grain and it helps to use a little radius. That is way more than you need. You should probably go talk to a sheet metal shop and have them make the parts and then you can finish up.

 

[Charles (in GA)]

Thats some stout material, you need to find a tin knocker shop to bend it for you, if they will. Take a serious brake to bend nearly eight inch thick material. I'd consider something thinner.

Not sure what a UTV is, but you would be well protected, thats for sure.

Charles

 

[bullnerd]

I would use 3003.Whatever is closest to .060,I forget. Its available from McMaster Carr. Very soft and can be bent with hands using some angleand clamps or tube to make a radius.Can be cut with hand shears so you should be able to do the whole job.Get a piece and try it out.

 

[broinkrist]

I always use 5052 for anything that requires bending. Pretty common and rather inexpensive.

 

[bullnerd]

5052 is also a good choice, but he mentioned not having a brake. Still pretty stiff to bend by hand.

 

[kmacht]

Yeah...Stay away from 6061...Doesn't care to be bent from my experience...Gets cracks or just plain breaks...But I'm usually using T6 (temper)...Anyone else with 6061 experience...?

I built an entire airplane out of 6061-t6 (sonex). Never had a problem bending or shaping it but had to use the proper bend radius. You can't bend it like a piece of mild steel

Keith

 

[500sks]

I will see if they have .063. Maybe that would make things easier.

 

[ilovevocs]

My choice would be 3003 h14. .10 would be overkill IMHO. .063 would be more than sufficient IMHO. Would fasten with dzus fasteners, roll the edge to match the catch and bead roll the interior of the roof for stiffness. Use foam tape like you use for a truck cap between the panel and the cage to eliminate vibration, some glue fabric to the interior panels as well to eliminate the rattle as well. Depends on your sensitivey to noise, bare panels don't bother me.

 

[purplezr2]

Charles, UTV, is like a ranger or rhino or similar side by side work vehicle.

That said for the cost of an OEM roof I bet it would be cheaper and better fitting then anything you can make at home unless you have some serious tooling.

 

[500sks]

Charles, UTV, is like a ranger or rhino or similar side by side work vehicle.

That said for the cost of an OEM roof I bet it would be cheaper and better fitting then anything you can make at home unless you have some serious tooling.

I don't doubt that I could buy one for not much more than I can make one, but then I have the satifaction of doing it myself. Half a sheet of .1 diamond plate is about $100. That gives me about $200 to get the bends made and if I can't get the spool gun to work I will have to take it to a local welder.

 

[sqaurelizard]

If you get the sheeting in the annealed form it would be pretty easy to get it heat treated after you've done all your forming. will make a really long lasting finished product

 

[jonski]

3003 is the right choice for bendability. If you were going to shear and weld it all together, 6061 is a better grade. I work in a tin shop and 6061 can be bent, just not at a 90 degree. 3003 can be broke at 90 and greater and can be welded just fine.

 

[500sks]

I talked to a couple of guys I know and now have access to a shear and a brake. we are thinking .040 or .063 and not diamond plate. we are thinking about bending the front over to make a hem and the rebending the hem into a gutter for the front and this would add stiffness. We are thinking of hemming the rear to stiffen that edge and making the radius on the brake a inch or so at a time. I am thinking about some rubber edge guard on the two sides that aren't bend over. What aluminum do I want 5051 or 3003? Can you hem aluminum with out cracking it.

 

[Kevin54]

3003 is the right choice for bendability. If you were going to shear and weld it all together, 6061 is a better grade. I work in a tin shop and 6061 can be bent, just not at a 90 degree. 3003 can be broke at 90 and greater and can be welded just fine.

It all depends on what temper of 6061. 6061-0 can be bent to 90 degrees very easily. We formed parts out of it all the time where I worked. You just can't put a sharp radius in it. You want the radius to be equal to, or larger than material thickness.

 

[pop pop]

Corrugated aluminum roofing is a 3xxx alloy.