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What material for doing ducting

Old 02-24-2018, 10:24 PM
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Default 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?
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Old 02-24-2018, 10:41 PM
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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.
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Old 02-24-2018, 10:49 PM
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Oh wow, that seems fantastic. Thanks a lot.
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Old 02-27-2018, 03:11 PM
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I just got the large roll of that stuff. I am looking forward to working on making ducting with it.
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