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At 09:23 AM 5/5/2006, you wrote:
1) What is correct aluminum to use for the baffling (between cowling and
cylinders)?
It seems the current material is 0.032" thick. I can't tell which alloy it
is though. Should I use 2024-T3? Or 6061-T4/6061-T6?
5052 T4 is easier to form and less likely to crack in the future than
other common alloys
2) The rivets all look like standard pop-rivets you get at a hardware store.
Is that acceptable? Or should I be using pounded/squeezed aviation rivets
like I see used on homebuilt airframe parts?
Pop rivets are often used to attach rubber to aluminum, but I
wouldn't use them for any metal to metal attachment. Pulled rivets
are extremely expensive compared to solid rivets.
3) What about the material for the sump baffling?
It seems to be 0.025" thick and reads AN-A-13-ALCLAD-24S-T (or something
like that... Hard to read).
24ST is the old designation for 2024. See comment above.
4) What is the best way to bend it?
I'm thinking of buying thick steel tubes of proper turn radius and pounding
the aluminum to match.
Pounding will work harden it in short order. Better if you can bend
it on a brake, or form it with a press. If you must pound it, try to
do it with a minimum of blows.
John Cooper, A&P
Skyport Services
PO Box 249
4996 Delaware Tnpk
Rensselaerville, NY 12147
518 797-3064
Fax 518 797-3865
www.skyportservices.net
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