Aluminium fabricators in GP?

[MikeBMW]

Hi guys,

I'm looking to replicate an OEM part that is plastic to aluminium. Who would be the best to talk to? It's a little complex as the connecting point at the one end is an elongated circle.

Here is an image of it. Doesn't need to look exactly the same, just needs to be bolt on.

 

[moranor@axis]

dont know what it is but i would worry about how the aluminium one flows looks like all the dents and curves were carefully designed...

 

[MikeBMW]

I understand that, but nothing ventured, nothing gained

 

[Hellas]

dont know what it is but i would worry about how the aluminium one flows looks like all the dents and curves were carefully designed...

It's aluminum, nothing a 4 pound hammer can't 'dent and curve' on a pipe like that

 

[Sankekur]

To machine those kinds of features might be a bit hard, but with a mould it should be possible to recreate all the features exactly.

 

[moranor@axis]

i would just get both flowed before i fitted the metal one...

 

[clutchplate]

hmm, I could say I'll draw you up some moulds in cad ... but I'll prolly mess it up ... it would acctually be quite easy to cast this in aluminium tho and just get the edges machined afterwards ... I'd say rather try look for someone would does casting .. they will prolly be able to hook you up ..

 

[Sankekur]

My idea would be to cast it as two parts then to join them afterwards, but I am not to sure how good (or possible) it is to join aluminium.

 

[mrv]

hey Mike.. what part is this?

 

[moranor@axis]

you cant cast aluminium if it is to take pressure because most of the time it come out porous dont think casting would be good for it but if you can find someone who can do a high quality cast it would be a good option

 

[Adi]

By far not an engineer here, however think think tha think plastic one could be used to create the mould.....then cast...

 

[moranor@axis]

yes you can cast it but if it comes out with Porosity you better off just using the plastic one unless its a low pressure part if you find someone that can cast it without Porosity it would be the best way to do it...
also if you cast it in two parts you will have to get it gas welded because other types of welding will also have Porosity in them

 

[Sankekur]

Maybe if they use an aluminium alloy they can cast it without being porous, if I am not mistaken BMW engines are cast out of aluminium and magnesium using a mould made of sand.

 

[applehero]

From what I recall, it's quite difficult to manufacture a part like that from aluminium. That plastic part was probably injection molded. You could always cast the part, although it won't really work for such a thin wall thickness and with complicated bends and fittings. My suggestion would be to keep as is... Where does this part fit onto and why you wanna change to aluminium?

 

[moranor@axis]

Maybe if they use an aluminium alloy they can cast it without being porous, if I am not mistaken BMW engines are cast out of aluminium and magnesium using a mould made of sand.

bmw will have the right equipment...but they dont like loaning it out

---

From what I recall, it's quite difficult to manufacture a part like that from aluminium. That plastic part was probably injection molded. You could always cast the part, although it won't really work for such a thin wall thickness and with complicated bends and fittings. My suggestion would be to keep as is... Where does this part fit onto and why you wanna change to aluminium?

you can build up the thickness on the outside of it before you cast it so you could cast it...porosity will still be a problem

you could...(im guessing you need something stronger and light weight) wrap it in carbon or glass fibre so it has less flex and take more pressure...

 

[calypso]

Ok my leftfield question, why do you want it in Alu? Isnt the plastic sufficient?

 

[born2boost]

Thats the air intake tube that leads to the airbox right?

I'm also trying to make something cool for my M3 track car...

 

[MikeBMW]

Thanks for the advice guys, much appreciated. Seems like quite a head ache to get done right. I'm going to give it a pass, I'll use my time more constructively on something else on the car

 

[moranor@axis]

you could always use the best tool every made...get some aluminium pipe and a hammer