Jimbo Posted July 1, 2013 Share Posted July 1, 2013 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 Link to comment Share on other sites More sharing options...
Deadman Posted July 1, 2013 Share Posted July 1, 2013 some pictures would help greatly . My first impression is your using the wrong material and the wrong adhesive https://www.shapeways.com/shops/a-10c-warthog-supplies https://forum.dcs.world/topic/133818-deadmans-cockpit-base-plans/#comment-133824 CNCs and Laser engravers are great but they can't do squat with out a precise set of plans. Link to comment Share on other sites More sharing options...
Jimbo Posted July 1, 2013 Author Share Posted July 1, 2013 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. Link to comment Share on other sites More sharing options...
agrasyuk Posted July 1, 2013 Share Posted July 1, 2013 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 :) Anton. My pit build thread . Simple and cheap UFC project Link to comment Share on other sites More sharing options...
Intrepid1 Posted July 1, 2013 Share Posted July 1, 2013 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 Link to comment Share on other sites More sharing options...
Deadman Posted July 1, 2013 Share Posted July 1, 2013 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 https://www.shapeways.com/shops/a-10c-warthog-supplies https://forum.dcs.world/topic/133818-deadmans-cockpit-base-plans/#comment-133824 CNCs and Laser engravers are great but they can't do squat with out a precise set of plans. Link to comment Share on other sites More sharing options...
Mike Powell Posted July 2, 2013 Share Posted July 2, 2013 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! Mike Powell www.mikesflightdeck.com www.mikesflightdeckbooks.com Link to comment Share on other sites More sharing options...
Deadman Posted July 2, 2013 Share Posted July 2, 2013 (edited) 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 https://www.shapeways.com/shops/a-10c-warthog-supplies https://forum.dcs.world/topic/133818-deadmans-cockpit-base-plans/#comment-133824 CNCs and Laser engravers are great but they can't do squat with out a precise set of plans. Link to comment Share on other sites More sharing options...
Jimbo Posted July 2, 2013 Author Share Posted July 2, 2013 Thanks for the advice guys, i'll give some of those ideas a go and let you know how I get on. Link to comment Share on other sites More sharing options...
grayson Posted July 2, 2013 Share Posted July 2, 2013 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 Link to comment Share on other sites More sharing options...
grayson Posted July 2, 2013 Share Posted July 2, 2013 But Deadmans right about using L shaped plates on the inner corners Link to comment Share on other sites More sharing options...
mulishaknight Posted July 4, 2013 Share Posted July 4, 2013 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. Link to comment Share on other sites More sharing options...
Duckling Posted July 5, 2013 Share Posted July 5, 2013 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. - - - - Link to comment Share on other sites More sharing options...
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