Aluminum Filler

[Pearson]

Re: Aluminum Filler

You can use the parafin as a sort of a buck. Or you can use it to rub out large areas instead of burning the skin off the heel of your hand. We had big blocks of it at shops where I worked long ago. But I have used the blocks you buy in the store melted together also. The stuff you buy in the store comes in too small of cakes to be useful for this purpose. You have to melt at least three of them together.

The nice thing about it is if you use it as a buck it has NO recoil. You can tap out little dings and creases with it pretty good. I mainly used it to rub out large dents where the metal wasn't stretched. It works better than a piece of wood. But you can also still use wood or whatever you like. It will work better if you smear some of the wax on first.

[Hank Jarrett]

Re: Aluminum Filler

NEAT tip! I'm going to try it this weekend.
Hank

The rubbed raw heel of my hand thanks you (leaving myself WIDE open to all sorts of comments).

[Len Petterson]

Re: Aluminum Filler

Interesting Discusion any hint where I can by a English Wheel?
Or just the wheels as I can build the frame.
Len

[mulwyk]

Re: Aluminum Filler

Getting back to Hals original question about fillers: my IA swears by a Poly-Fiber product called Superfil, sold by Spruce and others. It's epoxy based unlike Bondo type products that are polyester based. I've used it on my project with good results, but of course I can't say how it will hold up over time. The superfil is very smooth and easy to apply, and it takes an hour or so to set up so you have plenty of working time. (Bondo always seems to set up on me just as I'm applying it...leaving a streaked mess) Also, superfil, being epoxy, sticks like...well, epoxy. I've never had any chip or crack or break loose.

One hint: apply filler in thin, thin coats. Allow to set. Sand smooth. Then, if needed, another thin coat.

[Hank Jarrett]

Re: Aluminum Filler

Len,
Harbor Freight sells a cheap English Wheel (notice I said CHEAP, not inexpensive). It makes a nice base for a good (not great) English Wheel. If you can weld you need to add some stiffening structure to the top and back of the "C" that supports the wheels to keep them from deflecting (the little strap over the top is a joke). Alignment of the wheels under pressure is critical.
The nice thing is you really don't NEED a "great" Wheel to work aluminum. With a bit of rework the cheap one can become inexpensive. You also need to polish the wheels to a very fine finish to do good work and be VERY careful of those wheels. They will smash a finger or thumb so fast it won't hurt till you pull it out! Those wheels can do incredible damage to flesh and the sheet metal inertia will pull you in REALLY fast! We are talking LOOSE THE FINGER crushing on even a small wheel. BE CAREFUL AND ALERT WHEN YOU USE ONE!
Hank

[Hal]

Re: Aluminum Filler

Thanks for everyone's contribution. So what I take away from this is that I need a lot of practice bumping out dents. And if after all of my (or others') best work, if a very slight crease or depression remains I rough it up and fill it with a very thin skim coat of the polyfiber filler epoxy.

On a new topic, I have seen a lot about spring steel metal slappers on the internet in the last few days. Are these things of any use on aluminum? They seem to be used for stretching.

Hal

[Mark Julicher]

Re: Aluminum Filler

Slappers and spoons are great for taking out dents. The Big Whapper sold by Kent White (tin man tech) takes out larger dents and is leather faced which prevents stretching unless you go crazy with it. The objective is to tap down the high spots with a wide enough device to prevent the spot from popping up nearby. The width of the slapper does this neat trick.

You need a SOFT dolly to do this correctly. Shot bag is good most of the time. A lead dolly shaped to the work is excellent.

[Larry Lyons]

Re: Aluminum Filler

Interesting Discusion any hint where I can by a English Wheel?
Or just the wheels as I can build the frame.
Len

About a year ago a metal working hobbyist type mag. did a series of articles on building a full size ( large and heavy) english wheel frame. Very impressive machine and way more then I was prepared to get in to. I have all of the articles but one I believe. I can get you the name and an addy to get the full set if interested. They also had a place to buy the polished wheels for your frame when ready. Larry