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Aluminum Bracket Fabrication Guide: Tips and Techniques for Strong Components

Learn techniques and specifications for fabricating aluminum brackets to support components with high strength and corrosion resistance. Discover fabrication steps, tools, and finishing methods. Explore examples and costs for fabrication. Ideal for DIY enthusiasts and professionals. Master the art of creating durable brackets for various applications.

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Aluminum Bracket Fabrication Guide: Tips and Techniques for Strong Components

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  1. Bracketeering(BMAC Tech Tips) By Lenny Spall

  2. Nice looking bike..!

  3. Zooming in…

  4. Ugly bracket! Look at this!

  5. Purpose: to support or attach components, instrumentation & splash protection. Before After

  6. 5052-H32 Aluminum Specifications • Properties are good workability (useful in forming operations) • Good corrosion resistance, especially to salt water and fuel & oil lines • High fatigue strength and withstands excessive vibrations • Has the best welding characteristics of all the aluminums • Widely used for storage tanks, truck/trailer components, electronic chassis, etc. and parts requiring strength and good formability at reasonable cost. Frank uses 0.063” (~$3.50 per sqft) and 0.09” (~$6.30 per sqft) Aluminum sheets

  7. Bracket Fabrication & Fasteners Rivet Weld Bolt

  8. Fabrication Steps • Determine thickness of bracket • Determine how to attach • Make cardboard template • Fabricate with metal

  9. Fabrication Examples

  10. Aluminum Working Tools

  11. More Tools

  12. Finishing Aluminum • Nothing • Scotchbright • Polish • Paint • Powdercoat

  13. My Plane

  14. Inlet Air Deflector Panels

  15. Close up After Market certified panels = $450 each Fabrication costs: Materials $30 & Powder coating $30

  16. Vertical Stabilizer Leading Edge Panel After Market certified panel = $280 Fabrication costs: Material on hand; tools $12

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