What material for doing ducting
 

I was basically going to make ducting for my intercooler/radiator out of some sort of aluminum sheet. Larger areas (like the bottom area under the radiator) I would reinforce with bar stock. Everything held together with rivets or rivnuts.

I can acquire 5052 .04" thick in 4x8 sheets for about 85 bucks locally. Smaller sizes cheaper.
I can acquire 3mm dibond (basically .012 Al + poly + .012Al sandwich) in 4x8 sheets for 150 locally.
3mm dibond is the same weight as 1mm thick Aluminum (about 0.8 lbs per square foot)
I can get thicker/stronger metals for more money. For example, a 4x8 sheet of 2mm thick 5052 would be about 150 or so.

Is 1mm thick aluminum sheet strong/rigid/etc enough for my purposes?
Thoughts on dibond if any of you have used it?

1/8" Plastic Sheet Can be riveted, cut with saws, formed with press brake or heat.

I think I have some pictures in my build thread. Bronson used this as well.

Oh wow, that seems fantastic. Thanks a lot.

I just got the large roll of that stuff. I am looking forward to working on making ducting with it.

Hey......someone mention my name?
https://cimg4.ibsrv.net/gimg/www.mia...134a6c1945.jpg

After messing with the stuff I think I'll use aluminum angle riveted to the sheeting for the corners, makes for a much cleaner bend.

I like aluminum or regular ABS sheet. The benefit of the ABS sheet vs the HDPE roll, is that it doesn't fight you when trying to cut to shape and wants to hold an edge, whereas the HDPE keeps its memory and wants to perpetually try to curve/roll. I made the mistake of HDPE sheet this time around and had to add several stiffener pieces to it for that reason, and wish I had gone back to ABS for my inlet ducting.

What is a source for the ABS sheet?

The HDPE sheet likes a little heat to help set the bends. True about holding it’s rolled curvature, but did not find that too big a problem. I also have a lifetime supply.

I'm using road signs with a plastic core and aluminum skins on both sides. Kinda like alumalite without a honeycomb.

It's funny I find if i work the hpde when it's cold it seems to stay flat better. The aluminum angle on the corners also helps, if I could find the ABS as cheap I'd go that route but it's way way more expensive.

Most steel suppliers up here carry it that cater to the race shops, but I also get it from Piedmont Plastics (there's one in Greenville).

Pit Stop USA will mail it to you. I'm certain Summit and Jegs will as well.

Amazon carries Allstar plastic, pick your color
Works great, easy to cut and form.

Coroplast works great as well. Its a little more rigid than regular plastic sheet and a little less memory.

My friend uses political signs. They are holding up surprisngly well.