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Need an undertail cut from aluminum sheet

J

Junkie

gone for now
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Aug 23, 2006
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I need an undertail for a 1 off subframe. I have a large enough piece of .050" 6061 sitting around, but no good way of cutting it. I can do a paper template pretty easily, just need the aluminum cut to that. Size is around 2' by 1', the sheet I have is 2' square. Should be pretty easy with a jigsaw, bandsaw, or similar, I just don't have one and would rather not buy one for this. Shape is simple: the left and right have a single angle each, the top and bottom are both straight (and shouldn't need to be cut because height matches the sheet I have).

undertail.png


that shows the shape. 8" wide at top, 6" down to the bend, 11" wide at base, 2' total height... roughly.

If you can cut it to a paper template let me know, and what you'd want to do so.
 
I've made most of my own undertails from aluminun. An inexpensive tin snip you can pick up for less $10 will cut the aluminum just fine. As will a dremel if you dont have any power saws.

BTW, the only undertail I havent made was for my SV650 as I found this was on ebay so cheap ($24). Wasnt worth my time to make my own for the SV.

http://www.ebay.com/itm/SUZUKI-SV65...Parts_Accessories&hash=item4cfdc91a66&vxp=mtr
 
I've got a dremel and an angle grinder, but abrasive wheels are prone to clogging up with aluminum and it's difficult to make a clean cut with them. I've got some tin snips too, but they're difficult to cut something of this size with - and this is about the thickest that can be cut with them, anyway.

This is for a custom subframe on an SV1000, so I can't buy anything off the shelf for it.

IMG_0508.JPG


IMG_0509.JPG


it'll basically cover the entire underside of that.
 
Killer tail. Looks like a monster. Just re read your dimensions 2', not 2". Thats a long job for either the dremel or tin snips. I'd probably put a straight edge on the aluminum and put in a deep score in the aluminum and use the angle grinder with a thin cut off wheel, or even use my circular saw with an old blade on it. Not what a machine shop would do... but could work. If you were in the city, I'd take a stab at it with one of my saws. Clean up the edges by putting a slight chamfer on it with your dremel or angle grinder.

Love to see the finished project. I just finished converting my S to a naked with dual aztecs. Have a spare subframe and been toying with doing something like and old school BSA hump seat.

Good luck with the project.
 
Junkie said:
I've got ... an angle grinder, but abrasive wheels are prone to clogging up with aluminum and it's difficult to make a clean cut with them.
Click to expand...

Why not just go to the hardware store and get a cutting wheel for it? Clean cuts and it'll slice through that alum like it was soft butter.
 
What do you mean by a cutting wheel? I've got cutoff wheels for it, and it's a challenge to get a reasonably clean cut on something of that size with one.
 
I misunderstood: I thought you meant a grinding wheel was to abrasive and sloppy. A cut off wheel was what I meant. I've had pretty good luck with a cut off wheel and I just clean it up with a file or sander. Don't mind me and good luck.
 
You can cut aluminum with wood working tools, a skill saw will do the trick if you have one around.

Or just hack saw it, aluminum is soft enough it will go quick.
 
Hacksaw can't make a cut 2' deep, otherwise I'd use one.

Don't have a skill saw around either.

edit: and this is in Berkeley, not SLO.
 
If you have access to a Bosch jig saw,(call one of your carpenter friends), get a metal blade for it and it will make quick work of the piece you want to cut.
A trick you can use to keep from marring the aluminum surface as you cut through the aluminum would be to get some 1.5" wide blue painters tape and mask off the areas you are roughly going to be cutting through. Lay down the tape center line of where you are going to map out your cut and then draw your cut lines in pencil or ball point pen on top of the blue tape. Once you have your layout, take the sled of the jigsaw and mask it as well in blue tape. This will keep you from scratching up the surface as you cut through the aluminum. When done, peel all the tape up and run a fine file over all the cut edges. When using the file, keep it at around a 15 degree angle to the edge and it will remove all leftover burrs from your cut at the same time laying down a slight chamfer to the edges. Finish the edges with fine emory cloth and you're good to go.
I have made all my lic plate brackets and under tails this way. But hey, I'm a builder so I have all the tools needed... :teeth
 
If I still had access to our shop at school I'd help out, but they became douchey with who has access now days.
 
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