How I've been making custom brackets for my buggy

[rcx132]

This is a method I've found works for making custom brackets for my buggy build. It's absolutely not for everyone, but I'm faster with CAD and CNC than I am with an angle grinder. It also avoids late night noise that would otherwise annoy my neighbours. In this example, I needed a custom alternator bracket with 1mm accuracy to get proper belt alignment.

The method starts with first making a bracket out of plywood using a low cost 40 watt laser cutter. It takes several goes to get a precise bracket, adjusting the design after each attempt. I use superglue for the plywood because it dries almost immediately and is strong enough to support a 6kg alternator in this example. Once I have a plywood bracket that fits and works properly, I send the final drawings off for cheap eBay laser cutting.

I've made some pretty neat and elaborate brackets, and as always, forgot to photograph them until this last simple bracket.

 

[sg66]

They look nice and neat, I just chop and tack and make things up as I go along, they always work but probably not as neat as yours.....

 

[Beanwood]

This is a method I've found works for making custom brackets for my buggy build. It's not for everyone, but I'm fast with CAD and CNC, and its given good results. In this example, I needed a custom alternator bracket with 1mm accuracy to get proper belt alignment.

The method starts with first making a bracket out of plywood using a low cost 40 watt laser cutter. It takes several goes to get a precise bracket, adjusting the design after each attempt. I use superglue for the plywood because it dries almost immediately and is strong enough to support a 6kg alternator in this example. Once I have a plywood bracket that fits and works properly, I send the final drawings off for cheap eBay laser cutting.

I've made some pretty neat and elaborate brackets, and as always, forgot to photograph them until this last simple bracket.

View attachment 473569 View attachment 473570 View attachment 473571 View attachment 473572 View attachment 473573 View attachment 473574

Great idea- wish I had thought of it. Now I just need a laser cutter…

 

[Agroshield]

That is a good idea.

If CAD is cardboard-aided-design, you are using PAD.

A common form of construction in this area is tab and slot. Could you say a few words from experience if you have considered this.

As plywood is only available in limited thicknesses, do you have to do some extra thinking when the thickness of the plywood prototype does not match the eventual steel thickness?

Is there a minimum distance between parts on the laser cutter? To my short arms and deep pockets, what is shown looks to be quite wasteful of material.

 

[rcx132]

A common form of construction in this area is tab and slot. Could you say a few words from experience if you have considered this.

There's another recent thread on this. I use Solidworks, which isn't accessible to everyone. It has a built in tab and slot feature which I've only recently learnt to use, after this project.

As plywood is only available in limited thicknesses, do you have to do some extra thinking when the thickness of the plywood prototype does not match the eventual steel thickness?

If you're doing CAD models properly then the material thickness should be part of the basic geometry so it can be adjusted without altering the brackets outcome. So I can change it just before sending off for laser cutting.

Is there a minimum distance between parts on the laser cutter? To my short arms and deep pockets, what is shown looks to be quite wasteful of material.

No minimum distance. I buy the plywood as an 8x4 and cut it into squares ready for the laser cutter.

 

[bricol]

Don't forget spacers. Your bracket could have been less accurate, but accommodate a simple spacer to get the belt alignment.

I've taken on too many Yorkshire traits since living here to be using that much material .