So what i am looking to achieve from this is a completed alumunium build loaded with animatronics and a killer paint finish. The helmet i want to change up the mohawk and maybe tweek it here and there. I have yet to design the armor. I do have ideas for it and i have sketched some parts out. Once i do have a completed rendering i will post it. Please be honest i tell me what you think, good or bad. Any questions feel free to ask. Oh yes if anyone has a suggestion for me i am open to that as well. Thanx guys for viewing...GM
That's a good question. I am a chrome electroplater and we have a variety of bits that come in. I also have Metal-Supermarket, that's where i picked up my aluminum plate. But there are a couple of shops that i had worked prior- tin and copper plating that had a lot of aluminum parts just laying around so i need to check them from time to time. When all else fails if i can't find it, i'll make it...GM Lol i did'nt answer your question, did i. I wanted to work with metal but steel was out of the question as weight would have been an issue. Mix that with the fact that my welding skills are just at a novice level. So aluminum came to mind, but again i don't know how to tig weld. Now aluminum has been around since the 1800's, this i knew. Electricity has not, so how did they do it. After a lot of google time i came across aluminum brazing rods that can be used with a hand torch. So i had bought a couple and practiced. Now of course it is not as strong as a weld, it will come apart if you strike it hard with a hammer. But it is stronger than any resin build. I hope that this answers some of your questions. I hope to have a video showing the technique. Hey and thanx Honus for your support...GM
He has a lot of youtube videos too. The beauty of gas welding or brazing Aluminum vs. TIG is that the joint is much less likely to crack when performing rolling and forming processes post weld. If you anneal your Aluminum sheet it will hammer form very easily. The big trick is avoiding sharp bends as it will have a tendency to crack. I'd probably stick to 1100, 3003 and 5005 alloys as the higher strength 2XXX, 6XXX and 7XXX alloys will be much more difficult to work with. You can buy 3003H-14 soft sheet from Aircraft Spruce- I think a 4' x 8' .063" thick sheet costs around $100.
I know some jewelers that use a Meco Midget but I think they're a bit large for most bench jewelry work. I've been using a Hoke torch for the last 17 years and it works really well but I don't think it would be a good choice for gas welding Aluminum.
Ok honus i viewed quite a few vids on the gas welding and although that would be the best way to do things. I think i am going foward with the brazing method i stil find it incredibly strong for what i need. Just having a space for that equipment i just don't have right now. For the most part i'm working on my build at work but just recently it was suggested that i rent a work space for this project. As i am cheap i will just try and do thing on a mobil platform lol or at least till the bosses find out. Hehehe, thanx for all your help on this once again...GM
I am using 14 gauge aluminum. As far as cutting i am using the shops band saw, which is quite cheesy. But for the fine cuts i'm using a jewellers saw. Hoping to get my hands on a skroll saw. Tomorrow i want to check out the tool library down the street from me. Hoping to get my hands on a scroll saw and an english wheel. I am also looking to reinforce the build with brazing supports inside. I am hoping to keep the brazing out of sight. This weekend i am off, but i think i am going to the shop to do some work. I'll post the results...GM
I have an older Ryobi 16" scroll saw and it works pretty well for cutting Aluminum sheet of that thickness- the trick is using the right saw blade and use some WD-40 as a cutting lubricant. I think I paid around $60 for it on sale when I bought it new. It's probably one of the most used tools in my shop along with a bench top belt/disc sander. English wheels are super cool too. I'd love to have an english wheel and a power hammer...
Hi guys it's been awhile for me, just an update. I have damaged my arms at work and currently working on recovery. I live in Toronto and we have a place to borrow tools. It's amazing, it's called the Toronto tool library. They are offering a lifetime membership and I am asking you fine folks to go to their Facebook page and endorse me via likes or comments. www.facebook.com/TorontoToolLibrary?ref=hl&__nodl&_rdr Above is the link. I would like to say thanks in advance. This would really help me with my build and again thank-you... G.Murdoch