Dimebug Plans - Help

[Jimbo]

Hi All,

 

I'm working on the left and right consoles from Dimebug's plans, but I've hit a snag.

 

I have 16mm Square aluminium tubing that I'm using for the DZUS rails, but I cant figure out how to stick the corners together. I've mitred the edges and they have a clean, close fit but anything I do to join them is too weak.

 

I spent the weekend smearing it all in a ton of epoxy, gave it 2 days to cure and came in now to examine my handy work; which disintegrated when I picked it up :(

 

What technique is everyone else using? Any pointers appreciated.

 

Jim

[Deadman]

some pictures would help greatly . My first impression is your using the wrong material and the wrong adhesive

[Jimbo]

Hi Deadman,

 

As always, thanks for the quick reply.

 

This is the frame i'm trying to put together (pls excuse the crew chief :lol:):

 

 

You can see the mitred corners here (i'm not 100% this is the right thing to do):

 

 

with this epoxy:

 

 

Any pointers much appreciated.

[agrasyuk]

I'm not sure I can name one product where designers and engineers decided to use epoxy for connecting aluminum. Take it from pros, if welding is not an option use screws . Or at least rivets.

 

If you insist on gluing it increase contact surface (with side braces perhaps ) and get in a habit of not breathing that much when near it :)

[Intrepid1]

What might work better is to make angle sleeves that fit inside the corners than use the epoxy glue to fill in the gaps

that would increase the glues contact area without making the footprint larger

Randy

[Deadman]

well several thing are going wrong here, first your just using epoxy on dirty aluminum (the wrong type of adhesive) on the edge of the square tubing, not enough surface area for proper adhesion. I would suggest you use Extreme 310 from http://www.extremeadhesives.com/acrylics.php

and use a flat bottom plat cut from possibly 6061 aluminum 1/8 inch thick cut as a L and places on the bottom of the corner.

The following post give a get over view and some guidance on using adhesives on aluminum http://www.homebuiltairplanes.com/forums/aircraft-design-aerodynamics-new-technology/5293-conclusions-aluminum-adhesive-bonding-tests.html

Here is a vidio of a test on the adhesive

[Mike Powell]

I've seen moderately good performance from epoxy when bonding aluminum (see http://forums.eagle.ru/showthread.php?t=79768) However, I'm quite sure those bonds would not hold up to the abuse shown in that video.

 

I was not aware of the Extreme 310 product. Thanks, Deadman!

[Deadman]

Hi Mike i have used it on several non cockpit related projects where the heat from wielding the aluminum would possibly warp or distort the project out of spec with a properly cleaned material it bonds better and faster:thumbup: than other adhesives i have tried it will be used in some places on my project.

Edited July 2, 2013 by Deadman

[Jimbo]

Thanks for the advice guys, i'll give some of those ideas a go and let you know how I get on.

[grayson]

Hi There, you could try using JB-weld, got mine off ebay to glue Y2kiahs ally UFC box together, worked a treat.

all the best grayson

[grayson]

But Deadmans right about using L shaped plates on the inner corners

[mulishaknight]

Mine have custom made L brackets bolted to the inside spines with sheet metal (panels) bolted on to it. If I may suggest weld them up, with some brackets on each corner where you could bolt them to them to the front and back side of the console.

[Duckling]

One option to get it strong for a lifetime would be to bring the stuff a someone with a TIG welding equipment. Fixate the bars on the frame and a half'n hour with the TIG whould hold it for ever.