How To Bend Cast Aluminum Without Breaking It

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Topic: Sraightening a bent aluminum role.  (Read 15313 times)

Big Cake Jon

Whatever communication on bending (or unbending) cast aluminum?   The bracket that holds the foot pegs and rear of the exhaust on my 1000s has been bent in.  I am unable to discover a replacement (function 284435601) at whatever of the usual suspects, or reboot Guzzi spares in France, which was kind've my last hope.

And then I'm going to have to endeavour and straighten the bracket out.  I'thousand finding conflicting info on whether aluminum should/can be heated in social club to straighten the office, and if so, how much.  This is complicated by the fact that it may exist an blend or it may be the straight stuff.   Intuitively it seems that heating it a bit with a torch or over a stove (oven?) might make it more malleable, but some sources propose that this is (a) hard to do without catastrophic failure or (b) just won't lead to it being more malleable.   Anybody have knowledge?

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LeRoy (Bob Sharp)
Rochester, MI  UsaA.
'86 LM 1000 (since new in '86)
'79 V1000 G5 (equally of '08 and since sold)
'76 V1000 Convert (since November. 09)
'83 1000SP (as of Oct. 15)

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Andrew Thomas Evans

Aluminum melts at or effectually 1200f, and doesn't evidence estrus upwardly until information technology melts it also doesn�t cocky amalgamate as it sits which is why is cracks easier and doesn�t last every bit long in some applications every bit steel.

How I did information technology back in higher for an art grade, is that Flux starts to melt at around k'ish so I covered the aluminum in flux and took the estrus off once it started to become articulate. From there information technology was pretty easy to get the metal to do what I wanted, and a person could raise a bowl or something pretty fast with aluminum if they wanted, it gets really soft and moves effectually a fleck.
I didn't have to heat care for anything or make sure it was hardened as my application didn't telephone call for that - but information technology wouldn't be besides difficult to work harden it piece after it was straightened.  I�d just pound on it a scrap, not difficult plenty to move anything, but enough to put some pressure level on it.

Merely then again perhaps it�s an alloy that doesn�t similar to bend or oestrus upward and you�d merely end upwardly cracking it or something�

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Could in that location also be the same piece or similar from some other Tonti wheel - SP, Mille, T-3, T-five, etc that may exist easier to source and be a suitable replacement for yous 1000S piece?  Just a thought.

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'22 Royal Enfield Int650
'08 Triumph Bonneville T100

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Wildgoose Chase Moto Guzzi

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Could in that location too be the same piece or similar from another Tonti bicycle - SP, Mille, T-three, T-5, etc that may be easier to source and exist a suitable replacement for you 1000S piece?  Simply a thought.

Every bit a matter of fact, I recall the Le Mans Iv and V used the same, or very like, parts.

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LeRoy (Bob Sharp)
Rochester, MI  UsA.
'86 LM 1000 (since new in '86)
'79 V1000 G5 (as of '08 and since sold)
'76 V1000 Convert (since Nov. 09)
'83 1000SP (as of Oct. 15)

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I accept the 1000S sitting next to the LM IV.  I permit you know in a few minutes.  That's side by side to the T3.  The SP1000 NT is 3 thou miles away.

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From the Deep Deep South out in left field.  At that place are no stupid questions.  In that location are withal stupid people request questions.  🤣, this includes me.  😉

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Okay.....Only went downstairs.  LM 5, LM 4, Strada and !000S have the same crisscross/honeycomb mode mounts for the foot-pegs.  T3 has dissimilar style more of a straight rod merely mount to the same holes.  Probably anything else that has is a Tonti frame and no floorboards would fit.  Promise that helps.

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From the Deep Deep South out in left field.  There are no stupid questions.  There are however stupid people asking questions.  🤣, this includes me.  😉

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I would say you tin cold bend it back. I would non heat it because it doesn't human activity like steel.I remember once heating al with a torch when all all of a sudden it broke in half. :o

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1991 Lemans

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If you ever feel similar no 1 pays attention to you, try making a sandwich in front of your dog

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Curious that Lafranconi's of the era that were said to fit 1000s were not the same function for the LMIV.  The footpeg brackets were different.  That'due south what I think anyway.  Skillful to hear otherwise now from side-by-side comparisons.

Anyway, if that were my part and I wanted to curve it back, I'd strip the finish off to reveal any cracks, then put it in a hydraulic printing and work if very slowly.  It may exist more pot metal than alloy.  I bent ane on the LMIV and information technology snapped off when trying to bend it dorsum with a rubber dead blow hammer.

 ;D

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Roman, '86 LM 4

I drive way as well fast to worry well-nigh cholesterol

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Atavar

I have always been told that once a bandage aluminum part is bent it volition never be as potent again.  I am in no style a metallurgist then I practice not understand the why's and wherefore's.  the other fleck I was told (might be urban legand) is that aluminum has near no plastic stage when heating.  That is the phase with iron where if you heat it enough it gets softer and bends easier.  Manifestly with aluminum there are but a few degrees of temperature between solid and liquid.

If there are whatever metallurgists out there i would greatly appreciated getting educated on this with the real story.

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Big Block Jon

Cheers for all the help, everybody!

Plainly with aluminum at that place are just a few degrees of temperature between solid and liquid.

   This fits in with the warnings that some sources are giving about the dangers of heating, although Andrew Thomas Evans is telling the states that, at least with the pure metal, the temperature range between stage changes is much greater than that.

I was aware that the the Le mans (le manses?) from nearly 86 onward accept the same office with a different finish, so I've been looking for that as well, without success.  I didnt realize the office number was dissimilar. Thank you LeRoy.

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One, the part is definitely an alloy, zip is made from straight Aluminium, tin can't remember if it is too stiff and brittle or soft and squiggy. 2, if you google "bending aluminium alloy" in that location are a few conflicting methods posted around the place. My reading lead me to think that y'all may desire to gently heat the part to anneal it but no way do you want to attempt and heat information technology enough soften it. The other thing noted is that the part may well suspension and even if it doesn't it volition exist significantly weakened.
Sorry I can't bring whatever more positive comments

Steve

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aluminum can definitely exist straightened. information technology takes a deft mitt with the heat. I personally never become past a 95% repair.

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I have had good luck bending it back the same style it got aptitude.  Hitting it with a mallet and or protecting the piece with a block of forest to relieve the finish.  No luck with the hydraulic press.  And there are some things that volition just not reply to any method and just fail every bit soon every bit they are bent.  Locate a replacement first and things seem to work out. Try angle it first and be out of committee when information technology snaps.  Murphy's Law.  Mike

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I detect myself in the same state of affairs as Large Cake Jon - the right peg carrier is not only aptitude inward but is also twisted slightly. Any sage advice (in addition to the to a higher place) on how to straighten mine?

Search for a replacement has proved fruitless thus far. Stein-Dinse has the left-side, but non the right.  :(

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Charlie

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Is that a cast function, Charlie? I'm bold it is, which makes it tough. Aluminum historic period hardens.
Hither'due south what I would try. You'll have to anneal it, which takes 800 degrees. Fire up your acetylene torch, no oxygen, and make your function blackness with it.

Then, adjust to a neutral flame, and *carefully* fire the carbon off.

What you are trying to do is have the whole part of what you lot are trying to form at 800, so go on the heat moving constantly. When it'due south hot plenty, quench information technology in h2o. Only drop it in a bucket.  :o I know, you don't do that with steel, but this isn't steel.  ;D
If that doesn't do information technology, you gave it your best shot...
For instance, this hard aluminum piece would simply break if y'all tried to curve information technology without annealing..

Good luck!

« Final Edit: May 27, 2015, 10:32:xi AM by Chuck in Indiana »

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Chuck in (Elwood) Indiana/sometimes SoCal

 87 AeroLario
95 Skorpion tour
22 Royal Enfield Classic three fiddy
 "Two things are infinite: the universe and man stupidity; and I'k non sure about the universe."
Albert Einstein

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If it's bent beyond comfortable use, why not try to straighten it?

I've straightened cast aluminum successfully.

An entire industry has adult around straightening cast aluminum auto wheels with a bent rim.  Don't try to heat. Hydraulic pressure or a judicious rap with a wooden mallet is what I'd try.

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That'due south a very minor bend, so I wouldn't hesitate to put it in the press and advisedly bend it straight.  The argument against annealing it showtime is that information technology would then probably need to exist heat treated to prevent much easier angle in the time to come.  Just my opinion though, as they say, YMMV.

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When the Brussels sprout fails to venture from its lair, it is time to whorl a beaver upward a grassy slope.

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canuguzzi

If it's bent beyond comfortable employ, why non try to straighten it?

I've straightened cast aluminum successfully.

An unabridged manufacture has developed around straightening bandage aluminum machine wheels with a bent rim.  Don't try to estrus. Hydraulic force per unit area or a judicious rap with a wooden mallet is what I'd endeavor.

 :+one

Trying to slowly bend bandage aluminum is mostly a bad idea. The fast manipulation of the part is the style to try it.

Don't heat information technology. First, y'all demand to have a good and accurate way to measure the oestrus of the aluminum. Information technology is far more hassle than it is worth and is unlikely to work. If you tin can gamble breaking information technology, go for it.

For the typical home shop, access to hydraulic presses isn't usually an option. Yous likely have a vise, a hammer of diverse kinds and and so on. Don't brand information technology a ix day bicycle race. If information technology can become into the vise, secure it so as stated higher up rap it nice and good to bend it. Be prepared for information technology as well cleft.

For thinner aluminum parts, you don't need rut either. A quick bending effort is what works really skillful. Aluminum work hardens very quick and so you become ane, mayhap ii chances with thin stuff.

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 Some aluminum alloys tin be annealed by heating to 800 to 1,000 degrees and quenching in water.  That hardens steel just anneals aluminum or copper.
 If information technology breaks , you are no worse off than you were when you started.

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Sasquatch Jim        Humanoid, sort of.

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For something completely different...would it exist possible to refab the part out of a laser cut piece? CNC slice, or fab/weld some things together to replicate the part?

It looks fairly apartment with the peg brackets on it. Would not exist as well hard to replicate it and have it light amplification by stimulated emission of radiation cut or CNC or both.

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For something completely unlike...would information technology be possible to refab the function out of a laser cut piece? CNC slice, or fab/weld some things together to replicate the part?

It looks fairly flat with the peg brackets on information technology. Would not exist too hard to replicate it and have information technology laser cut or CNC or both.

It'due south a fairly intricate role. Replicating it would be costly no matter how information technology was done.

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Charlie

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Bring on cheap 3D copiers! Perhaps in a few years there'll be one in every second garage - copy the part at abode, send the file out to be fabricated up.

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2010 V7 Classic, 2014 V7 Special
1996 1100 Sport Carb (in NZ), 2004 V11 LeMans (in UK)
Carberry Enfield 5-Twin, 2008 Imperial Enfield Electra, 2006 RE Electra 535

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Mike is right. If you purchase an available replacement and then try to straighten the original, it will work flawlessly.

If you DON'T purchase a replacement, information technology'south guaranteed to break during the attempt, and suddenly no replacement will be available.

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That's the combustion chamber of the turbo shaft. Information technology is supposed to exist on fire. Y'all just don't usually see it but the case and fairing fell off.

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canuguzzi

Some aluminum alloys can be annealed past heating to 800 to i,000 degrees and quenching in water.  That hardens steel but anneals aluminum or copper.
 If it breaks , you lot are no worse off than you were when you started.

If it breaks it is completely unusable. Pretty sure that qualifies as FUBAR.

Maybe infinite the function from the other side to business relationship for the bend and at least gets things somewhat aligned? Might not be real pretty but might exist functional until a better solution is at mitt?

« Last Edit: May 27, 2015, 04:17:twoscore PM past Norge Airplane pilot »

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I don't know... if information technology breaks, it's still almost probable weldable.

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When the Brussels sprout fails to venture from its lair, it is time to roll a beaver up a grassy slope.

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Some other old timers fox is to rub bar soap on the role before heating.  When the lather turns blackness the aluminum is the right temperature for working.  Don't do this with a disquisitional role you don't have spares for, information technology is as probable to break as bend.

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2008 Norge - Black Wing Squadron

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protrude

What leafman60 said. It bent quick, and so straighten quick. No heat. I've had to straighten the bandage restriction lever on my Griso twice.

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Remember that the part is cast, not wrought. Totallyy different grain structure. A fiddling research. With metals sites will givecrecommendation due south on common cold formability of cast aluminumvalloys.

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Jonathan K
Marblehead, MA

1981 V50III "Gina"
2007 Griso 1100 "Bluto" (departed but not forgotten)
2003 EV "Lola" gone to the "Ridin' Realtor" in Peoria
2007 1200 Sport "Ginger"

"Who's the true cat who won't cop out, when there's danger all most?"  -Isaac Hayes

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