Going to go pick up some aluminum today to start work on an intake. How thick should i get? Also is there a certain grade that works and welds better than most. I won't be forming it, just making a few straight bends.

Thanks
Randy

 

Aluminum MIG wire is 4043, so I would assume 4043 would be the ideal material to use. However 6061 and 5052 are less expensive.

 

I would use 6061

 

my current manifold is made from 6061 square 4" tube for the plenum. i'm making a new one this winter out of formed sheet aluminum. i'll probably use about 1/8" thick sheet.

 

I usually use 1/8" 6061.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by k20 jon &raquo;</TD></TR><TR><TD CLASS="quote">I usually use 1/8" 6061. </TD></TR></TABLE>

Wanted to say k20 jon. You have some very nice looking welds on your site. Awesome work.....hopefully I'll get there some day

 

a gooid alloy to use is 5052 h32 very easy to work without cracking or splitting. Welds very well with 4043. If you need to do allot of forming work you may want to choose 3003 which is the alloy amny pans are made out off
090--.120 6061 would not be my choice it is way to hard to work with .

 

1/8" 6061 would be good for a simple box design intake manifold

 

This should be helpful.
http://www.ez.org/aluminum.htm

6061 doesn't form worth the crap in the T4 or T6 heat treats. I've never tried to form it after annealing though. The 6061 that you can normally find is heat treated. If you try to form it any appreciable amount, it will end up with fatigue cracks.

Personally, I like 5052, although I am interested in trying out the 5086/5083 alloys.