i need to make some intercooler ducts out of sheet alu what i want to know is that thickness to use is 1mm or should i use 2mm or 3mm

I wouldn't use 1mm, you can bend it with your hands and it will not last imo. 3mm would be unnecessarily thick so just stick to 2mm if possible.

bend it with you hand mite be ok if you have to use a little force i just dont want to end up fighting with it so 2mm then

I'd use 1.5mm myself

I bought the Japtek ones to fit my larger SMICs. Haven't actually fitted them yet, but still.... :lol:

If only you could plastic weld.

I bought the Japtek ones to fit my larger SMICs. Haven't actually fitted them yet, but still.... :lol:

 

had a look no one has them in stock

I bought a set of intercooler ducts that ended up coming from Australia, they were a tidy kit, but required so much to be removed to fit the bumper they were a very expensive failure. Making them yourself would be the best bet, but making them fit your bumper and around the crash bar will take some trial and error.

 

I suggest mocking up each shape in stiff cardboard before cutting aluminum sheet.

3mm is far too thick, the correct spec that you need for the job will likely crack when you bend it. Even 2mm is too thick for this job. Once bent to shape, 1.5mm will be super strong but you'll have to ensure you've prepared the edges properly before bending to avoid cracking. My advice would be to use 1mm as it will bend with minimal risk of cracking but will still be more than adequate structurally.

 

Have you any idea how much sheet material you require to cut the templates from?

These guys were made from .032" (.08mm) aluminium. The pictures in the link also show the construction method.

 

http://www.twinturbo.net/nissan/300zx/forums/general/view/2341516/My-latest-project-Intercooler-ducting.html

 

the sheet alu is really cheap to buy. so will give it a bash when the car comes back from paint will try 1mm and seen how i get on