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Looking for help with a small custom sheet aluminum job

  1. #1
    truncated phrase here trider143's Avatar
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    Looking for help with a small custom sheet aluminum job


    I want to make a small flat bracket to mount a RAM mount or Go Pro on a Ducati Supersport, using 3/16" sheet aluminum. The finished piece is about 3 1/4" x 3 1/4, with two holes drilled to 3/8" D.

    This will attach to the two chicago screws attaching the plastic housing around the ignition.

    A crude mock-up using hardboard is shown to illustrate the cutting needed. The critical dimensions and cuts are hole locations and the ears around the holes to avoid the housing.

    Any suggestions where to get this done? (I am in metrowest area, but some travel is OK too.)

    Looking for help with a small custom sheet aluminum job-img_2159-jpg

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  2. #2
    Member Johnpewpew's Avatar
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    Re: Looking for help with a small custom sheet aluminum job

    I'll look and see if I got some scrap laying around.
    3 1/4x3 1/4 square. By 3/16 thick. With 2 3/8 holes drilled. Where do you need the holes drilled on the plate?

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  3. #3
    truncated phrase here trider143's Avatar
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    Re: Looking for help with a small custom sheet aluminum job

    Quote Originally Posted by Johnpewpew View Post
    I'll look and see if I got some scrap laying around.
    3 1/4x3 1/4 square. By 3/16 thick. With 2 3/8 holes drilled. Where do you need the holes drilled on the plate?
    The critical dimensions are 2x 0.375" holes 2.1" separated and then a 0.575" radius cut around the bottom 1/2 of the holes. The rest of the can be straight and dimensions are less critical, and I could try with a jigsaw.

    Looking for help with a small custom sheet aluminum job-img_2160-jpg

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  4. #4
    Member Johnpewpew's Avatar
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    Re: Looking for help with a small custom sheet aluminum job

    Ok let me see what I got laying around

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  5. #5
    Member Johnpewpew's Avatar
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    Re: Looking for help with a small custom sheet aluminum job

    No dice on the 3/16" thick aluminum. I got 1/8"

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  6. #6
    truncated phrase here trider143's Avatar
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    Re: Looking for help with a small custom sheet aluminum job

    Appreciate you checking.

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  7. #7
    Lifer Falko's Avatar
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    Re: Looking for help with a small custom sheet aluminum job

    How professional do you want it? If you want something that looks factory, I've had things done at ET Duval in Leominster. They have a water jet, they'll CAD it up and cut it out. Pricey though for that one piece. If you want to just cut it out and sand/file/polish it over time to a good look, I might have a chunk of metal lying around here.

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  8. #8
    truncated phrase here trider143's Avatar
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    Re: Looking for help with a small custom sheet aluminum job

    Quote Originally Posted by Falko View Post
    How professional do you want it? If you want something that looks factory, I've had things done at ET Duval in Leominster. They have a water jet, they'll CAD it up and cut it out. Pricey though for that one piece. .
    Well, depends upon the Supersport market size.
    FWIW - I was on group ride a week and half back, and there were 4 brand new Supersport Ss on the ride!

    Thanks for the pointer. I will check, does not hurt to ask.

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  9. #9
    Member Johnpewpew's Avatar
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    Re: Looking for help with a small custom sheet aluminum job

    I can do it out of steel. I got 12g steel laying around

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    Member flippedr6's Avatar
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    Re: Looking for help with a small custom sheet aluminum job

    If you give me a few other dimensions I can draw it in Solidworks and water jet it out. I have a ton of stock at work I'm sure I have the 3/16


    edit or if you want send me the template I can measure and compare before I send it back.

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    Last edited by flippedr6; 08-03-17 at 02:13 PM.
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  11. #11
    Member Johnpewpew's Avatar
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    Re: Looking for help with a small custom sheet aluminum job

    Quote Originally Posted by flippedr6 View Post
    If you give me a few other dimensions I can draw it in Solidworks and water jet it out. I have a ton of stock at work I'm sure I have the 3/16
    That's better than what I can do lol

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    truncated phrase here trider143's Avatar
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    Re: Looking for help with a small custom sheet aluminum job

    Quote Originally Posted by flippedr6 View Post
    If you give me a few other dimensions I can draw it in Solidworks and water jet it out. I have a ton of stock at work I'm sure I have the 3/16
    Outstanding offer. I will work up a detailed drawing tonight!

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  13. #13
    Lifer joeswamp's Avatar
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    Re: Looking for help with a small custom sheet aluminum job

    Aluminum is incredibly easy to cut and file, you could cut it with a jigsaw slightly oversize and then file/drawfile the edges to the line. Drill the holes with a drill press and you're done. You can buy raw material at Home Depot (overpriced but you're buying such a tiny quantity that it doesn't matter).

    Although I agree it is much easier to find someone with scrap and a waterjet cutter.

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    Re: Looking for help with a small custom sheet aluminum job

    Quote Originally Posted by flippedr6 View Post
    If you give me a few other dimensions I can draw it in Solidworks and water jet it out. I have a ton of stock at work I'm sure I have the 3/16


    edit or if you want send me the template I can measure and compare before I send it back.
    I have attached a PDF with more detailed dimensioning that I think (hope) is sufficient to enter into CAD.

    Thank you very much, and let me know if I missed anything in the drawing.

    Attachment 47811

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    Member flippedr6's Avatar
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    Re: Looking for help with a small custom sheet aluminum job

    Will do man I should be able to do it tomorrow.


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    Re: Looking for help with a small custom sheet aluminum job

    There's a metal shop in Woburn mass and they sell sheets to bar stock.


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  17. #17
    Member flippedr6's Avatar
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    Re: Looking for help with a small custom sheet aluminum job

    Quote Originally Posted by imstuner View Post
    There's a metal shop in Woburn mass and they sell sheets to bar stock.


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    If you are talking about Metal Mart on 6th avoid avoid it. They are so over priced its crazy. There is Admiral metal over near BJ's but they dont sell smll stuff.

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    Re: Looking for help with a small custom sheet aluminum job

    Quote Originally Posted by flippedr6 View Post
    If you are talking about Metal Mart on 6th avoid avoid it. They are so over priced its crazy. There is Admiral metal over near BJ's but they dont sell smll stuff.
    Thanks for the tip and I'll go check it out.

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  19. #19
    Lifer joeswamp's Avatar
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    Re: Looking for help with a small custom sheet aluminum job

    Quote Originally Posted by flippedr6 View Post
    If you are talking about Metal Mart on 6th avoid avoid it. They are so over priced its crazy. There is Admiral metal over near BJ's but they dont sell smll stuff.
    Metal Mart is really pricey, but they're sort of the only game in town for small quantities. I've been curious as to the best place to buy mild sheet steel in the Boston area -- especially 19 gauge.

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    Re: Looking for help with a small custom sheet aluminum job

    Quote Originally Posted by joeswamp View Post
    Metal Mart is really pricey, but they're sort of the only game in town for small quantities. I've been curious as to the best place to buy mild sheet steel in the Boston area -- especially 19 gauge.
    I looked for ages when I lived in Boston proper & never found a good resource. I ended up going to Metal Mart. Yeah, they're pricey, but no one else is willing to bother with such low quantities.

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    Lifer Stromper's Avatar
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    Re: Looking for help with a small custom sheet aluminum job

    Mc Master Carr

    You should be ablw to hack that out with a jig saw , and a file

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  22. #22
    truncated phrase here trider143's Avatar
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    Re: Looking for help with a small custom sheet aluminum job

    I finally have the bike, bracket, and hard-to-find-dimension-off-the-shelf sex change screws all in the same place today. Installed the bracket, mounted the gopro and took it for a test ride. Worked out great, and I have now have a nicely-centered and stable camera mount for the 2017 Supersport, just in time for track day.

    Huge thank you to flippedr6 for building the bracket for me - perfectly done!

    Bracket installed:
    Looking for help with a small custom sheet aluminum job-img_2325-jpg

    With gopro installed:
    Looking for help with a small custom sheet aluminum job-img_2326-jpg

    Frame grab from test ride video:
    Looking for help with a small custom sheet aluminum job-screen-shot-2017-09-08-a

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  23. #23
    Rookie Rada's Avatar
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    Re: Looking for help with a small custom sheet aluminum job

    Looks mint. Nice work

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  24. #24
    Senior Member AEG's Avatar
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    Re: Looking for help with a small custom sheet aluminum job

    You might want to adjust the camera to not record your speed on the street ... just in case Looking for help with a small custom sheet aluminum job

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  25. #25
    truncated phrase here trider143's Avatar
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    Re: Looking for help with a small custom sheet aluminum job

    Quote Originally Posted by AEG View Post
    You might want to adjust the camera to not record your speed on the street ... just in case Looking for help with a small custom sheet aluminum job
    that is why I posted the frame grab and not the video

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