Aluminum for chassis

[Lindz]

What grade of aluminum is typically used in chassis?

Utility? 5052? 6061? other...

thanks!

[LeftyStrat]

It can vary, I think 6061 might be most common. If you want aircraft grade, that would be 7075. It is the highest strength. Both 6061 and 5052 have good corrosion resistance. Just stay away from 2024, it has copper as the main alloy and doesn't resist corrosion as well.

[jborders5]

5052 or 6061 will work great. I've spec'd chassis in both & choose based on current cost & availability.

[steve_p]

5052-h32 is what you want if you are bending.

6061-t6 will crack at the bends unless you use a very large bend radius.

Steve

[Lindz]

Thanks guys

I am familiar with the various aluminum grades in general but for a very different purpose - I make ski, snowboard, skateboard and wakeboard manufacturing equipment (and boards) for a living. I use 6061, 7075, and Titanal daily but in a very different capacity, with either mellow bends for molds or in actual ski and board construction as a load bearing layer. I'm not at all familiar with 90 degree bends or what would be appropriate for for amp chassis

For my new amp hobby I thought I would take a crack at building something completely from scratch this time as I have the gear necessary in house , but was not sure what grade was commonly used.

.090 seems to be the most common thickness - correct?

Next step is faceplates - the graphics printing tech I have in house for boards and skis might work pretty well for them. If my prototypes work out I may be able to offer them to other builders for a decent price and an alternative to what people are using now

[boots]

I used to obtain old retired street signs from the local recycling center for use in ham radio projects, but as Steve said, it tends to crack when you bend it, so I gave up on that.

Still, it is a cheap source of aluminum sheet for non-critical applications. You just have to work around the bullet holes.

[Reeltarded]

What caliber for an octal socket?

My brother has a beat up STOP sign, and now you have me plotting.

[pula58]

Aluminum oxidizes. So, how do you get a good ground connection to the chassis?

[steve_p]

Aluminum oxidizes. So, how do you get a good ground connection to the chassis?

Chromate conversion finish prior to powdercoat.

[Lindz]

OK I'll bite.. I realize aluminum oxidizes over time but it seems like a lot of the chassis out there are aluminum so what do people do besides live with it? seems like most builds I see just bolt to the chassis.. Solder?

For a hobby builder would you then recommend steel assuming a proper treatment for the aluminum is cost prohibitive?

[Tillydog]

Aluminum oxidizes. So, how do you get a good ground connection to the chassis?

It's not an issue - make a solid mechanical connection and you're good to go. (Anodised parts should be taken back to bare metal at the connection.)

Plain 'half hard' 1000 series aluminium is fine for chassis, too and is easy to work with.

As long as you don't want to paint it (for which there is no need), aluminium is a lot easier to work with than steel, IMHO

0.02p

Andy