Re: [bolger] Aluminum Teal started
curtisbetts@...wrote:
The AL comes from the mill in a coil that is typically from 10,000 lbs
to
20,000 lbs. A cut to length line is then used to uncoil, straighten,
flatten,
cut and stack the sheets. This same machine will label and apply
protective
sheet if desired.
I used to fix these machines (and many others) for a living. :-))
These are not cheap ($2000 to $4000) but you can sell the machine and
get
your money back after finishing the project.
Oh yes, get an electronic welding helmet, there are soooooo nice to use.
:-))
HAVE FUN
michael
>Great!
> Yesterday I picked up a sheet of 1/8" aluminum "5086" and started to
> build Teal.
> But, aluminum doesn't always come in 4x8 sheets. The best price IYou can get AL in 6' x longer than any boat you want to build.
> got was from a distributor who handles 6x20 sheets. And they had one
> in the warehouse cut to 6x14. So I had them cut 2 16" x 14' pieces
> for the gunwales, leaving 40" x 14' for the bottom and everything
> else. Cost: almost $400. The 14' panels let me stretch the boat
> out from 12' to around 13.5', on the same beam. Less than
> Windsprint's 16' though.
The AL comes from the mill in a coil that is typically from 10,000 lbs
to
20,000 lbs. A cut to length line is then used to uncoil, straighten,
flatten,
cut and stack the sheets. This same machine will label and apply
protective
sheet if desired.
I used to fix these machines (and many others) for a living. :-))
> Now to find a welder...Look for a 250 amp, industrial MIG welder, preferably with a spool gun.
These are not cheap ($2000 to $4000) but you can sell the machine and
get
your money back after finishing the project.
Oh yes, get an electronic welding helmet, there are soooooo nice to use.
:-))
HAVE FUN
michael
Curtis:
Interesting project - keep us informed.
A couple of years ago, I bought a small wire feed welder for an aluminum
project. I think it cost a couple of hundred bucks, but it was easy to
learn, and it worked great. I later sold it for almost what I paid for it.
Is that the way you are heading?
Chuck
<snip>
Interesting project - keep us informed.
A couple of years ago, I bought a small wire feed welder for an aluminum
project. I think it cost a couple of hundred bucks, but it was easy to
learn, and it worked great. I later sold it for almost what I paid for it.
Is that the way you are heading?
Chuck
<snip>
>
> Now to find a welder...
>
>
>
>
>
Yesterday I picked up a sheet of 1/8" aluminum "5086" and started to
build Teal.
As I've noted before, a lot of Bolger's boats would
be perfect in metal, but I've never used the stuff before. Teal
seemed like the right size and complexity.
I faxed a note to Bolger asking for suggestions, and Susanne called
me back the next evening. She suggested Windsprint as being better
able to handle the extra weight of aluminum. But it's longer, more
complex, and probably too big to handle for little kids. Further,
Payson's literature advertises Teal as 93 lbs, and the 1/8" metal
weighs "only" 55 lbs for a 4x8 sheet.
But, aluminum doesn't always come in 4x8 sheets. The best price I
got was from a distributor who handles 6x20 sheets. And they had one
in the warehouse cut to 6x14. So I had them cut 2 16" x 14' pieces
for the gunwales, leaving 40" x 14' for the bottom and everything
else. Cost: almost $400. The 14' panels let me stretch the boat
out from 12' to around 13.5', on the same beam. Less than
Windsprint's 16' though.
So, with a 4 month old helper, I picked up the materials, set out a
couple old pallets in the driveway, and started cutting. With my
assistant, it took about 5 hours to cut temporary frames out of
plywood scraps, assemble the gunwales (with drywall screws), put the
bottom on, scribe and cut it, and turn the boat right side up. Also
in this time were several bottles, soothing back to sleep (the saw is
pretty loud, and dropping the panels on concrete makes a big bang),
and a bunch of diapers (be very careful when you are covered with
aluminum shavings).
The boat is now outside in the rain, if it lets up a bit I will make
some cardboard deck and bulkhead patterns and cut them out.
A few notes on aluminum: 1/8" is about as flexible as 3/8" plywood,
but weighs a bit more than 3/4". I cut it with a 5" cordless saw,
and an old carbide wood blade (bought a special aluminum blade at
Home Depot, but wrong size arbor). This is very noisy and slow,
compared to wood, and required several battery changes. When cutting
aluminum, wear socks. The shards on bare face, arms, and legs aren't
too bad, but when they are hot and land inside your shoes, it's
uncomfortable. If the baby is asleep, move him across the yard.
Other costs to date have been for safety goggles, metal yardsticks, a
couple 2x4's to rip down for gunwales, etc.
Now to find a welder...
build Teal.
As I've noted before, a lot of Bolger's boats would
be perfect in metal, but I've never used the stuff before. Teal
seemed like the right size and complexity.
I faxed a note to Bolger asking for suggestions, and Susanne called
me back the next evening. She suggested Windsprint as being better
able to handle the extra weight of aluminum. But it's longer, more
complex, and probably too big to handle for little kids. Further,
Payson's literature advertises Teal as 93 lbs, and the 1/8" metal
weighs "only" 55 lbs for a 4x8 sheet.
But, aluminum doesn't always come in 4x8 sheets. The best price I
got was from a distributor who handles 6x20 sheets. And they had one
in the warehouse cut to 6x14. So I had them cut 2 16" x 14' pieces
for the gunwales, leaving 40" x 14' for the bottom and everything
else. Cost: almost $400. The 14' panels let me stretch the boat
out from 12' to around 13.5', on the same beam. Less than
Windsprint's 16' though.
So, with a 4 month old helper, I picked up the materials, set out a
couple old pallets in the driveway, and started cutting. With my
assistant, it took about 5 hours to cut temporary frames out of
plywood scraps, assemble the gunwales (with drywall screws), put the
bottom on, scribe and cut it, and turn the boat right side up. Also
in this time were several bottles, soothing back to sleep (the saw is
pretty loud, and dropping the panels on concrete makes a big bang),
and a bunch of diapers (be very careful when you are covered with
aluminum shavings).
The boat is now outside in the rain, if it lets up a bit I will make
some cardboard deck and bulkhead patterns and cut them out.
A few notes on aluminum: 1/8" is about as flexible as 3/8" plywood,
but weighs a bit more than 3/4". I cut it with a 5" cordless saw,
and an old carbide wood blade (bought a special aluminum blade at
Home Depot, but wrong size arbor). This is very noisy and slow,
compared to wood, and required several battery changes. When cutting
aluminum, wear socks. The shards on bare face, arms, and legs aren't
too bad, but when they are hot and land inside your shoes, it's
uncomfortable. If the baby is asleep, move him across the yard.
Other costs to date have been for safety goggles, metal yardsticks, a
couple 2x4's to rip down for gunwales, etc.
Now to find a welder...