Ally plate forming

[Cone]

So Ive planned to make my own luggage plate for the husky, I am getting a set off ally plates delivered and am planning to cut them using a jigsaw and drill, i only have basic tools. Any hints or tips for making a nice job, has anyone done this before and successfully?

A plan below is what i want at the end.

This could be a complete disaster

[Cone]

94C305A2-4219-4B08-9BD7-C5E34D3FB4D1.jpeg (88.3 KiB) Viewed 4016 times

[Rederic]

Take it easy and keep the speed low on the jigsaw you might find it easier if you use a lubricant, paraffin is very good on aluminium
Try and keep the plate you are cutting clamped down
It sometimes made easier if you was to put your holes in first a bit smaller than you Need then use these holes to screw a sacrificial piece of plywood under the plate and cut through them both together this stops vibration and you blade getting jammed up.
You can then open you holes up when it’s cleaned up
It makes it look neater like that as well
Yalso cover the plate with masking tape to help keep the marks down
It’s a easy job so long as you don’t rush it
And don’t forget to wear safety glasses you will need them

[Brenhden]

Take it easy and keep the speed low on the jigsaw you might find it easier if you use a lubricant, paraffin is very good on aluminium
Try and keep the plate you are cutting clamped down
It sometimes made easier if you was to put your holes in first a bit smaller than you Need then use these holes to screw a sacrificial piece of plywood under the plate and cut through them both together this stops vibration and you blade getting jammed up.
You can then open you holes up when it’s cleaned up
It makes it look neater like that as well
Yalso cover the plate with masking tape to help keep the marks down
It’s a easy job so long as you don’t rush it
And don’t forget to wear safety glasses you will need them

This is really good advice

[bowber]

As Redic said, take your time and don't try to shortcut it.
I remember my dad spending days making engine plates from Durel sheet by chain drilling then hours of filing to shape, they looked good when he'd finished though.
I then became and engineer and we had hydraulic copy mills at work so I could make a couple of sets in the hour before work. That's the definition of an engineer, we're lazy and get machines to do all our work for us

Steve

[Venusian]

Where is recommended for buying small sections of Ally plate?

[Cone]

I bought from Ebay, it was £8 300x300 sheet

It came with an plastic coat, would you still tape over it? I suspect tape is more hardy.

If i make a good job of them im either going to paint them or powder coat them - depending on how much it is to do so.

[Benson-1215]

For folks in the South Wales area try CG Rees under the flyover in Cardiff.
What gauge aluminum are you using ?

[Cone]

Lol 4mm that would have been useful as I was ringing round places to see what they made but no one did orders small enough for me

[Benson-1215]

If you have problems cutting it give me a shout i put it up on a milling machine to help a ABR out.
I am sure i have a set of Radius gauges in the garage if you want a lone.
the other tips mark it out with engineers blue or use a 1-1 scale auto cad drawing to mark your centres out If you want an A3 template let us know. and to get a good finish draw file all edges.
AND REMEMBER THE ENGINEERS LAW MEASURE TWICE CUT ONCE.

PS good luck