SFA all aluminium canopy

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Stef
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SFA all aluminium canopy

Post by Stef »

The beginning of our rendition of a canopy; we're not professional aluminium fabricators but not looking too shabby so far

2 full days' work and 2 basic frames done; I now understand why these things are so expensive...it's a lot of work!! Cutting & welding the angles is really time consuming, not too mention the fact that aluminum really warps so there is a lot of checking/measuring in between welds.

IMG_20170809_155653_450x600.jpg

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Last edited by Stef on Mon Dec 04, 2017 7:21 am, edited 1 time in total.
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Re: SFA all aluminium canopy

Post by Mud Dog »

Looking good so far Stef! :thumbup:
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Re: SFA all aluminium canopy

Post by Hilux Heap »

Looking Good :thumbup: . I'm in line for one as well :D: :beg:
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Re: SFA all aluminium canopy

Post by Stef »

Let's see how these two...well 3... turn out. If you still like what you see I could twist some arms to build #4; don't have a price yet but I doubt if it will be much cheaper than the commercially available ones.

Next step is to get some rubber & figure out the doors...want to try something different. Also not going to use alu tread plate so there is some more TLAR'ing to be done
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Re: SFA all aluminium canopy

Post by Mars »

Baie netjies. Met wat sweis julle? TIG?
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Re: SFA all aluminium canopy

Post by Hilux Heap »

Sure thing Stef :thumbup: . It's all about rhe price LOL :D: :D:
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Re: SFA all aluminium canopy

Post by Stef »

Mars wrote: Thu Aug 10, 2017 8:49 am Baie netjies. Met wat sweis julle? TIG?
Tx :thumbup:

Jip ... TIG met Argon en dun rods. Moes eers 'n pro kry om ons 'n les of twee te gee...maar my mater wie se masjien dit is kom nou mooi reg en ek gaan self bietjie probeer hopelik een van die dae.
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Re: SFA all aluminium canopy

Post by Mars »

Ja as mens daardie TIG eers regkry is dit ongelooflik wat jy kan sweis!!!!
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Re: SFA all aluminium canopy

Post by pieta.swanepoel »

Ek sal maar volg wat julle doen. Moet self leer swys. Dalk eers met ietsie kleiners begin :)
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Re: SFA all aluminium canopy

Post by Stef »

No real progress over the weekend; work among other things...
The fancy gull wing doors to give level access right to the top of the roof inside are not going to work out so lekker with the elements and some of the dimensions, plus it would be an awful waste of the cladding sheet (besides, I hardly ever load right up to the roof anyway).
So the design is being adapted slightly so that the roof skin is closer to the width of a sheet (within 50 mm as opposed to 200 mm), and one sheet basically yields two roof skins. This means that smaller panels are needed for the side doors.

Aiming to have the door frames & gussets done by the weekend
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Re: SFA all aluminium canopy

Post by Bugzy »

Stef, hoekom se jy die Gull Wing Doors gaan nie werk nie - ek beplan om my canopy so te bou so ek sal graag wil weet hoekom jy so se.
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Re: SFA all aluminium canopy

Post by Stef »

Hi Buks, eintlik omdat ons heeltemal te opgewonde geraak het oor die aluminium sweisery :laugh2:

Die tubes wat tussen voor en agterste "arches " loop is te naby aan die hoeke in gesweis, maw die deur se raam bo gaan by die kontoer vd "arch" verby steek. Hulle moes minimum 10mm nader na die middel toe wees vir dit om te werk met 20mm raam.
En om die gull wing te doen beteken ook dat jy nie nog 'n tube kan insit tussen voor en agter op die onderste hoek vd arch nie, so mens verloor bietjie strukturele sterkte. Na oorweging of ons moet sny en skuif, het ons toe maar besluit om eerder te gaan vir sterkte as die ekstra moeite vir 'n 100mm wat jy wen boontoe, jy sal dit in elk geval kan bykom van agter af. Plus die cladding werk beter uit met die grootte van 'n sheet.
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Re: SFA all aluminium canopy

Post by Stef »

Not too much progress made in the last 3 weeks, but in saying that, we are on door design #3, got the cladding & rubbers procured, and some of the cross bars front to back welded in.

This week managed to get 4 x door frames cut & welded together; yesterday the flat bar came in so this is what we ended up with for the final side door assembly:
IMG_20170914_215055_800x600.jpg
IMG_20170914_214930_450x600.jpg
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Re: SFA all aluminium canopy

Post by Stef »

Frame #3 all welded together; slightly beefed up with an extra arch and using 3mm wall thickness as this one will have an RTT.
Rear door frames welded together for all 3 frames.
IMG_20170925_131422_600x450.jpg
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Re: SFA all aluminium canopy

Post by Stef »

First 2 frames now look like this
IMG_20170920_211821_450x600.jpg
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Re: SFA all aluminium canopy

Post by BernhardSmuts »

Hi Guys.

This project looks awesome!

We're also pretty keen to start a project similar to this. I have been researching quite a bit and the info on the Forum is AMAZING!

If possible could you give me an idea of what size aluminium tubing and sheeting you guys are using for your canopy and where you bought it from?

Hilux Regards
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Re: SFA all aluminium canopy

Post by Stef »

Thank you Bernhard,

There are plenty weird sizes available in Aluminium... :mrgreen: We based our choices on what was available at the local suppliers as places like Huletts would only manufacture on demand with a min qty of 500 lengths IIRC.

We opted for 38mm & 32mm square with a 2mm wall; as mentioned above the third frame has the same but with 3mm walls which is plenty strong but also 50% heavier.
38mm is used for the arches and 32mm for the beams, this is to give a 6mm gap so that the cladding and adhesive will sit on the 32 flush between the arches.
Same concept followed with door frames, used 20x10mm and 3mm flat bar leaving 6mm gap. Reason for the thin door frames is so that the door as well as the rubber seals could all fit within the 38mm of the arches.

I personally do not like tread plate as a skin for canopies; I went for a composite aluminium & HDPE cladding used on buildings that has good wind loading & anti vibration properties. The outside is also pre-coated with a UV resistant coating. I'm also of the opinion that it would have good thermal insulation properties. Downside: hideously expensive and min thickness is 4mm

The aluminium was purchased mostly from NFM in Pta and Eurosteel in Jhb...Eurosteel also has alu plate with nice finishes other than tread plate, as well as normal alu profiles. Seals I got from Pro-auto rubber. Lock & hinges came from Trail Acc in Silverton.
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Re: SFA all aluminium canopy

Post by Stef »

"Side" project...
IMG_20171013_175457_600x450.jpg
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Re: SFA all aluminium canopy

Post by Mud Dog »

Coming along nicely Stef! :thumbup:
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Re: SFA all aluminium canopy

Post by Stef »

Welding all done. Just the finishing, powder coating & final assembly left

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Re: SFA all aluminium canopy

Post by Mud Dog »

Looks neat Stef! :thumbup:

Any reason why the one has a transverse rip on top while the other two have lateral ribs?
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Re: SFA all aluminium canopy

Post by Stef »

Mud Dog wrote: Mon Oct 23, 2017 8:44 am Looks neat Stef! :thumbup:

Any reason why the one has a transverse rip on top while the other two have lateral ribs?
Tx Andy. Really pleased with the way it turned out

To answer your question...Yes, but it's really just a third arch exactly the same as the front & rear ones with the same lateral beams between arches as the other two frames.

The design was adapted for an an over landing rig so basically 2 reasons :
1) It will have a RTT fitted hence the third arch to spread the load.
2) The guy wanted split side doors.

You'll also note that it doesn't have 3 lateral beams, only 2 and these are welded further in towards the middle to exactly match the mountings of the RTT. The middle beam on the other 2 is meant to support the cladding but we didn't deem it it necessary with the reduced span
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Re: SFA all aluminium canopy

Post by BernhardSmuts »

Awesome! Looks great so far and thanks for the info on all the materials used.
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Re: SFA all aluminium canopy

Post by Stef »

IMG_20171203_123530_800x600.jpg
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IMG_20171203_123737_800x600.jpg
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Re: SFA all aluminium canopy

Post by Mud Dog »

Neat!! :thumbup: :thumbup:
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Re: SFA all aluminium canopy

Post by GeorgeJvR »

Sjo Stef daai Bakkie lyk mooi! :thumbup: :D: :beg: :beg: :beg: :thumbup:
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Re: SFA all aluminium canopy

Post by Mars »

Uitstekend!!!!!
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Re: SFA all aluminium canopy

Post by Stef »

:thumbup: Dankie

George jy sal moet uithaal want die prys is belaglik :mrgreen:
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Re: SFA all aluminium canopy

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Stef wrote: Mon Dec 04, 2017 11:42 am :thumbup: Dankie

George jy sal moet uithaal want die prys is belaglik :mrgreen:
:lmao: :lmao: :lmao:
Ek spaar hard meneer. :D: :D: :D:
Geniet hom, maar pas hom op :taunt: :laugh2: :taunt:
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Re: SFA all aluminium canopy

Post by Bliksempie »

Baie netjies Stefan. Het hom laasweek gesien toe jy by Prys uitdeling was (skool). Lyk regtig goed.
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Re: SFA all aluminium canopy

Post by Stef »

Bliksempie wrote: Wed Dec 06, 2017 7:02 am Baie netjies Stefan. Het hom laasweek gesien toe jy by Prys uitdeling was (skool). Lyk regtig goed.
Tx Robbie

Het seke nog die oranje stickers op gehad :mrgreen: Moes ma so ry met hom want ek hy is nou ongemaklik om aleen af te haal met die cladding op LOL
Skies ek't jou nie gesien nie..?
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Re: SFA all aluminium canopy

Post by Bliksempie »

Stef wrote: Wed Dec 06, 2017 7:40 am
Bliksempie wrote: Wed Dec 06, 2017 7:02 am Baie netjies Stefan. Het hom laasweek gesien toe jy by Prys uitdeling was (skool). Lyk regtig goed.
Tx Robbie

Het seke nog die oranje stickers op gehad :mrgreen: Moes ma so ry met hom want ek hy is nou ongemaklik om aleen af te haal met die cladding op LOL
Skies ek't jou nie gesien nie..?
Geen probleem, en jys reg. Die stickers was nog op.
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Re: SFA all aluminium canopy

Post by GeorgeJvR »

Stef wrote: Mon Dec 04, 2017 11:42 am :thumbup: Dankie

George jy sal moet uithaal want die prys is belaglik :mrgreen:
Dink jy nie jy moet een vir 'n V6 vigo bou nie :D: :stir: :surrender: :surrender: :surrender:
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Re: SFA all aluminium canopy

Post by Stef »

GeorgeJvR wrote: Wed Dec 06, 2017 8:11 am
Stef wrote: Mon Dec 04, 2017 11:42 am :thumbup: Dankie

George jy sal moet uithaal want die prys is belaglik :mrgreen:
Dink jy nie jy moet een vir 'n V6 vigo bou nie :D: :stir: :surrender: :surrender: :surrender:
As jy ernstig is kan ons gesels maar ek moet eerlik wees die materiaal aleen was omtrent die intree prys v die komersiele ekwivalent, waarvan die cladding aleen seker 43% was. Sal hoor of daar enige aptyt is om nog te maak
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Re: SFA all aluminium canopy

Post by Mars »

Net vir interssantheid. Wat het die materiaal gekos?
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Re: SFA all aluminium canopy

Post by Stef »

op die stadium geskat op min R8 000 per canopy, moet nog al die fakture bymekaar tel.

Net so rofweg:
Cladding is R2600 per sheet en ons het 4 gebruik , dus so R3600 uit die R8k.
Slotte skarniere, lifters,rubbers R2500
Powder coating R830
Boute, moere & rivnuts +- R200
3 tubes Soudaflex R250
Alu tube skat ek so R1500


Dan moet mens nog goed soos welding rods, gas ens. inreken.

As jy self 'n canopy wil ontwerp en laat bou dan begin van die ouens op R23k, so seker nie te sleg uitgewerk nie
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Re: SFA all aluminium canopy

Post by Bliksempie »

Gald nie sleg nie. Dis wat myne ook omtrent gekos het. Ook alles self gedoen
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Re: SFA all aluminium canopy

Post by Stef »

Bliksempie wrote: Wed Dec 06, 2017 12:41 pm Gald nie sleg nie. Dis wat myne ook omtrent gekos het. Ook alles self gedoen
Moet se ek is verbaas dat Alu nie veel duurder as gewone staal is nie
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Re: SFA all aluminium canopy

Post by Bliksempie »

Stef wrote: Wed Dec 06, 2017 12:45 pm
Bliksempie wrote: Wed Dec 06, 2017 12:41 pm Gald nie sleg nie. Dis wat myne ook omtrent gekos het. Ook alles self gedoen
Moet se ek is verbaas dat Alu nie veel duurder as gewone staal is nie
Presies hoekom ek maar vir Mild steel gegaan het. As daar 'n 5kg verskil is, dan is dit baie asook die feit dat ek dit dan self kon weld. Ek is maar hardegat as dit by iemand anders se handewerk kom. :surrender:
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