Making alloy cowlings. UK.

[blue up]

I've built lots of cars in the past, 1930s to 1950s, and have had to learn how to manufacture panels from scratch.

Are there any skilled panel bashers who could give me some pointers as to how to deal with any requirements specific to aircraft cowlings? I'm in the Cardiff/St Athan area. I'd expect there are many more practitioners of the art over in the US than there are in the UK. I also need to find a source of sensibly priced sheet ali (3000 series?) so would welcome any suggestions.

I've been through the 'Bingelis' books and have asked around but have yet to meet anyone who has actually done the job, rather than just seen it being done.

Many thanks

Rob

[dubbleyew eight]

the alloy selection is the key.
you need a dead soft aluminium. 1100, 1200, 3003 or maybe 5005.
thickness just under 1mm.

I have watched as 2024 was used. needed lots of annealing.

small stuff can be beaten but most aircraft stuff is done on an english wheel.

Tony Bingellis is not the best reference. find the videos done by John Glover on aircraft english wheel work and you will be learning from a master.

there is also a "How to make your own English Wheel" booklet that was done by Cal Davis many years ago that details construction of John Glover's Wheel.

aluminium source in Australia is Capral (formerly Comalco) ask for soft to half hard sign aluminium.

[Jon Starr]

I'm interested in this too so I looked up those references.

You can get both the videos and the book on how to build the wheel from John Glover's site. Prices seem pretty reasonable.

http://www.metalcrafttools.com/video.html
Metalcraft Tools Books

Cheers,

Jon

[dubbleyew eight]

I'm told that locally to me a Tigermoth engine cowling was done in 2024 with wire wrapped edges. it cracked and was withdrawn from service within a week.
replaced in soft aluminium the replacement has shown no deterioration in ages.

[blue up]

Thanks guys.

I already use an English Wheel, shrinker etc for making panels, mostly in steel and then either MIG or TIG weld them. Tigging ali is a bit of a PITA and not my favourite subject. I'm making a 1/4 scale replica Bentley Blower rad cowl at the mo in 1050 soft ali. Very fiddly to get it right and not burn through. About 2 days to fabricate and polish it. Most of the ali sheet I use is either 1.2 or 1.5mm

2024 is somewhat prone to cracking, even with 404x TIG rods so I've usually used 1050 cheapo stuff since I can't find any 3000-series sheet locally.

First test bit of Bentley cowl to work out the correct starting shape...

[NutLoose]

I would register and ask on here, there are a lot of people in the Historic side of things in there, such as People from ARCO and Airframe Assemblies.

Historic Aviation

Indeed might be worth dropping HFL a line as they are based at Saints doing the Gannet, they also have a thread on there

HFL Hunters and Gannet at St Athan

As for metal, LAS do smaller bits if needed I think, see

Raw Materials

[blue up]

Thanks, NutLoose.

I'll give all of them a try.

PS Nearly finished.

[Golden Rivet]

Have you asked your engineering colleagues to see if anything can be 'ordered'...

[blue up]

Can't get a 1m x 2m sheet of ali in my crew bag.

[blue up]

Locost. Good idea. I'll give them a try.

The photos of the stuff I've made are all in low resolution for a good reason. Bending metal is a lot easier than it looks, Just whack it with a hammer. The skill I lack is in bending it into the right shape. Lots more practice required!

[dubbleyew eight]

blue up I think you're a champion boy. keep at it.