Chassis Materials

[Graw]

So HDPE is lighter than I expected, very good thickness to weight ratio. Whats the best way to go about fixing HDPE? My design involves angled bits for those nasty spinners - no 90 degree angles lol. So brackets? Tapping it for the shape I need would be a pain I think, but if it would be better tapped I'll put some time into it (Maybe a combo of tapping a few bolts for the bulkheads into the base along with brackets and brackets for the outer armour.)

That is also a great idea maddox, that base must be bombproof! And cheers higgeh I just was hoping to get an idea of how tried and tested HDPE as a base is for a feather thats all.

[maddox10]

I fix HDPE with about any means possible. Ranging from wood screws to bending and welding.
From Ranglebox nutstrips to selfmade barrelnuts. Even Titanium brackets with rivnuts and bolts.

[R9000]

I've been going M6 barrel nuts and tee nuts all the way with my design. Right pain in the arse to get the two right-angled holes aligned properly though. XD I didn't know you could weld HDPE? What do you melt it with?

[maddox10]

HDPE is a thermoplastic material, and it's commonly welded with a hot air gun and a specialised nozzle to feed the filler material.

I use the same hot air gun (not the cheap paintstripper stuff, but a fully adjustable Leinster) to bend HDPE.

[Graw]

I thought about using thick and coarse woodscrews, stronger than you'd think I imagine? Interesting about the welding, does the heat not make it warp though?

[maddox10]

If you do it right, the welding doesn't distort the HDPE.

And woodscrew don't cut the cheese. T and barrelnuts are the better options.

[Graw]

I might test my plastic welding skills on some offcuts lol

[overkill]

With the proper heat gun, welding is really easy - I figured it out in about 5 minutes after watching a couple of videos. For thick and structural parts of a frame, I would still use barrel nuts; they are likely to be stronger and allow you to replace damaged sections.

[maddox10]

Nick, you figured out TIG welding , and TIG welding Ti after watching a few video's. It seems you're a natural.

But yes, HDPE welds tend to be more brittle than the base material and benefit a lot from some metal reinforcements.

[overkill]

Hardly a natural, I still suck at welding steel for some reason. Another reason for getting set up to weld HDPE is that the hot air gun can also be used for heat forming - 5mm HDPE bends very easily and 10mm bends with a bit of patience.

[alexc]

Hi Guys,

I've been thinking about chassis material recently too..... I'm considering using a 3.5mm Mild Steel Angle welded to make a frame chassis then bolting HDPE (6, 8 or 10mm depending on weight) as easily replaceable armour panels.

Does this seem like a daft idea? (I'm thinking it might be as I don't see anyone else suggesting this method )

Cheers,

Alex

[Graw]

Im sure a much more experienced head will help you out but that sounds like a fine idea to me, I take it that you are building a feather?

[maddox10]

A basic steel angle "wireframe" with bolted on HDPE sheets. Works.
But I would suggest using other material than DIY grade steel or even worse, cheese grade ali.

I know at least 1 feather that uses hardox strips to connect the sheets.

[alexc]

Thanks for the info guys..... I think I'll stick with the Steel Angle chassis with HDPE Pannels bolted to it, but maybe the Mild Steel Angle I picked up cheap from my local B&Q that was shutting down isn't the best...

Cheers,

Alex