Aluminium body panels?

[Rogerborg]

I'm thinking of doing some filler side panels for my new GPZ 500, in between the top fairing and the belly pan. Like chuff am I paying ~£80 for plastic ones, so I was pondering just knocking something up out of aluminium.

In a previous life I made a kit car bonnet out of aluminium, but that was quite some time ago, so I'd welcome suggestions for an appropriate thickness to use. There's just a gentle, simple bend to go in it, plus I'll likely fold it over at the edges and make it good with filler. So, 2mm? More? Less? Should I use something else instead? Any reason I shouldn't do it? Won't go with the twisted subframe?

https://i42.tinypic.com/6rpkbr.jpg
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Biking is 1/20th as dangerous as horse riding.
GONE: HN125-8, LF-250B, GPz 305, GPZ 500S, Burgman 400 // RIDING: F650GS (800 twin), Royal Enfield Bullet Electra 500 AVL, Ninja 250R because racebike

[Vincent]

Should look good, not something I'd attempt mind. You had a look around at anything suitable off other bikes, (cars, boats, jetskies, lawn mowers etc), that you might be able to shoehorn in place?
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[Ariel Badger]

2mm sounds about right, you know how to anneal ali? You rub it in hand soap and heat until the soap blackens.. any hotter and it will melt.
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[Pete.]

14 or 16 gauge seems suitable. You'll need etch primer to get paint to stick to it.
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[Nexus Icon]

You might think £80 is a lot of money but how high do you value your own hourly rate? It's going to take you hours to do a half decent job and it would probably still look better with the right parts.

Seriously, buy the plastics and spend the hours saved enjoying the bike, not hitting your thumb with a hammer.
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[Rogerborg]

Eh, fettling isn't my day job. I likes me a bit of bodging time in the shed.

14 - 16 gauge is 1.5mm. That, or 2mm?

Good call on the acid etch, I'd forgotten about that particular bit of fussing around.
____________________
Biking is 1/20th as dangerous as horse riding.
GONE: HN125-8, LF-250B, GPz 305, GPZ 500S, Burgman 400 // RIDING: F650GS (800 twin), Royal Enfield Bullet Electra 500 AVL, Ninja 250R because racebike

[Pete.]

16 gauge is easy to remember - 1.6mm or so

https://mdmetric.com/tech/steelthk.htm
____________________
a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[Ariel Badger]

[Nexus Icon]

[Robby]

Just get some used ones off ebay, or fix up what you have.

Ali will be a bastard to shape, then will probably rattle a lot. It'll also look balls.

[DrDonnyBrago]

Presumably it functions fine without the panels so why bother?


I am sure there are other parts of the bike that could benefit from the time and attention more and if you are just worried about the cosmetics, eat less pies, lose the hi vis and sellotape a paper dragon to your helmet.

[Ichy]

Is it one of these on ebay ?

If so then it is a fairly complex shape to form. You will need to weld the flanges to get the depth of some of the edges correct.
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[chris-red]

Put some braided lines on it first.
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Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

[Rogerborg]

I've updated the image at the start of the thread to highlight the area.

Why? 'Cause.

There's none to be had used.

If they look balls, I'll bin them.
____________________
Biking is 1/20th as dangerous as horse riding.
GONE: HN125-8, LF-250B, GPz 305, GPZ 500S, Burgman 400 // RIDING: F650GS (800 twin), Royal Enfield Bullet Electra 500 AVL, Ninja 250R because racebike

[Pete.]

You could get at least 4 or 5 neons in that gap.
____________________
a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good