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Anyone with experience of making metal sidepanels please?

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Anyone with experience of making metal sidepanels please? Empty Anyone with experience of making metal sidepanels please?

Post by yammydave Mon 15 Jun 2009, 18:57

Apologies for being off subject, but have a bit of a problem someone may have previous experience of.

Becuase I've changed the total look of my CB750/900 I needed to make some one-off sidepanels.
That in itself wasn't any bother, just make a cardboard template for some ally sheet.
However I wanted form to them so have beaten them out to the shape I wanted.
Problem is that in order to shape them without access to presses and the like I've used thin 1.5mm sheet and now I need to reinforce them to get rigidity.
I was thinking about maybe using plumbers lead solder in large quantities on the backsides might stiffen it up.
I know they used to fill dents in bodywork in the olden days with lead solder, but believe it can fall out!
Other thing I've thought about is covering them in fibreglass and bodyfiller but again I'm concerned that it might not adhere properly and fall off.
Any help would be appreciated.

Anyone with experience of making metal sidepanels please? Gardenshots002
Anyone with experience of making metal sidepanels please? Gardenshots018
yammydave
yammydave
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Post by griz Tue 16 Jun 2009, 22:26

Nice work mate, I used to love hammering alloy into shape at school Laughing I would use a good flexible body filler, lead may work but I'm not sure how well it will stick to alloy? I think there's no reason why a good filler won't hold.

Why not buy a small amount of filler & apply it to some spare alloy plate & give it a good testing to see how it stands up?
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Post by Fringe Tue 16 Jun 2009, 22:59

Dave,
What about that duraweld stuff ya used on the casings?
Would that bulk them up or tack on some ali stretchers across the back of the panels?
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Post by yammydave Wed 17 Jun 2009, 22:11

Fringe wrote:Dave,
What about that duraweld stuff ya used on the casings?
Would that bulk them up or tack on some ali stretchers across the back of the panels?

Like that idea of stretchers very much thanks Fringe.
It would be too expensive to bulk them up but strengthening with bridging pieces certainly does make sense.
yammydave
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Post by grim1 Wed 17 Jun 2009, 22:20

Only trouble is if its anything like lumiweld is the heat required will probably destroy your thin panels.How about if you use chemical metal to fix pieces of mesh to the panel so you have something for the fibreglass to adhere to properly?Just score the areas rough so chemical metal has a key?Just another idea.I was involved years ago in sheet metal work but if anything required strengthening ribs were added by tig welding.I take it using thicker guage ali is a no no?
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Post by yammydave Thu 18 Jun 2009, 08:41

grim1 wrote:Only trouble is if its anything like lumiweld is the heat required will probably destroy your thin panels.How about if you use chemical metal to fix pieces of mesh to the panel so you have something for the fibreglass to adhere to properly?Just score the areas rough so chemical metal has a key?Just another idea.I was involved years ago in sheet metal work but if anything required strengthening ribs were added by tig welding.I take it using thicker guage ali is a no no?

Thanks Grim1.
Thicker sheet might have been an option but I already had this and no money for anything that is not essential (had to wait a fortnight to afford a £30 starter solenoid!).
With no access to TIG the common approach of having to make do with whatever I have available has to determine the outcome.
The bike is that close to being finished it is a little fustrating, though it's been around 3 years since I started putting it back together!
All the more so in that once finished it will be going up for sale and so I need to ensure that the next owner isn't going to have problems with it all falling apart.
The ribs approach does seem the most feasible because I can allow for the instrusion of the starter starter solenoid on the left and rear master cylinder on the right.
Both are close to the edge and if I used mesh covered by fibreglass it would I think go someway but not fully, towards addressing the problem.
The chemical metal does seem a good idea but whilst I appreciate they are probably much improved never had very good results in the past.
Because the panels are vertical and subject to vibration I'm a bit reluctant to use it.
With all three of you offering some worthwhile ideas I've a feeling these may end up incorporating a mix of them!
yammydave
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Post by grim1 Thu 18 Jun 2009, 08:45

Crazy idea here.What about that expanding foam stuff?I know its not the easiest to work with but you can shape it and its very sticky?
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Post by Deathace Thu 18 Jun 2009, 21:58

A Simple yet effective way to strengthen them would be to Powder Coat them, it would be the final finish for the panel and also adds thickness/stability to any metal.

worth a shot?

Russ
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Post by Fringe Thu 18 Jun 2009, 22:26

I used 1.5mm Ali for my battery tray. no distortion if the heat is right. ie not too much or too little.
I still think its the best way and I know you can do it Dave.
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Post by yammydave Fri 19 Jun 2009, 09:17

Don't know what I was worried about.
Scuffed the inside of the panels, covered with resin and then used Grim1's idea of the ally mesh followed by a layer of fibreglass matting and then covered in resin.
This morning as stiff as a starched shirt! sunny
Thanks lads.
yammydave
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Post by Fringe Fri 19 Jun 2009, 12:21

Cool
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