Custom bending a custom extrusion

[brokenrinker]

I mangled the aluminum extrustion that wraps around the top of a boat windshield. Finding a replacement, new or used, appears to be, out of the question.

Among other machine tools, I have access to a wire EDM so it's conceivable I could make an extrusion die but I have no idea how to extrude the part or how to bend it once that's done.

Any suggestions or starting points?

[mikek10]

To bend it you would need tooling and probably need to fill the gaps in the extrusion to prevent collapse.

The same is true if you were to try to get someone to bend it for you - they would need to tool up

Best bet is the original manufacturers I'm afraid.

[69dblcab]

busted rinker.
I would try the OEM if still in business.
You showed where it goes but not how badly mangled.

It maybe with patience and skill be repaired.
The next best idea would be to replace all of the top trim. Maybe not original but would all match.
Third would be to find close extrusions and build something up to near duplicate original.

Depends on exactly what you wnat for an end result.

Cheers
Dudley

[brokenrinker]

Thanks for the responses.
I suppose someone more talented than me might be able to bend the damaged extrusion back into shape but it has kinks and ripples and even a melted spot. I've worked at it some but it is very hard to match the contour of the windshield.

I'd love to know how they do stuff like this in the first place. I'm not picky about what the cross sectional profile of the extrusion looks like. I could replace the whole thing, but no matter what extrusion I end up using I've got to figure out how to create that compound bend required to make the thing fit.

[mikek10]

Bending its not that hard IF you have the right tooling and equipment - which would be very expensive and certainly many many times the cost of what you are trying to make. For that reason you would be better off trying to obtain one from the makers

[brokenrinker]

The boat is an orphan. Company folded around 2000. I've found one outfit that supplies many of the boat manufacturers with these window frames but they didn't make it and didn't know who might have.

[neilw20]

Ever thought of making a fiberglass surround.
Make a positive with a spoke shave or router.
Make a mould. Make em whatever color you like.
Easier than making an extrusion die.
They usually want you to take 5 or 10 lengths so what do you do with the rest?

[69dblcab]

I ebayed "rinker" and got several boats that appear similar and up to 2007.

Maybe more eyes looking and a great picture of your mangled extrusion.
and a good picture of the profile would help you and us in helping you.

Cheers
Dudley


from my days in auto industry. Tension and bend over mandrels for curves.
One off would be by hand and forms.

[brokenrinker]

Didn't mean to mislead. I've been using "Brokenrinker" for a long time. The Rinker was my previous broken boat. The current broken boat is a Celebrity.
Thanks for the input.

neilw20 - fiberglass would be great but how would I make a mold for this weird shaped thing.

These are links to some more pics . . .

http://s214.photobucket.com/albums/c...t=extrude5.jpg

http://s214.photobucket.com/albums/c...t=extrude4.jpg

http://s214.photobucket.com/albums/c...t=extrude3.jpg

http://s214.photobucket.com/albums/c...t=extrude1.jpg

http://s214.photobucket.com/albums/c...t=extrude2.jpg

[69dblcab]

bumbling around I googled and found a review on a new boat with the same windshield manufacturer as your boat.

try their customer service and explain your issues.
you may be able to get a piece from baja boats or they may link you to their supplier.

http://www.boats.com/news-reviews/article/fine-latitude

some other possibly useful links

http://forums.iboats.com/showthread.php?t=220264

http://www.iboats.com/Marine_Store/dm/prod_id.52313

Cheers
Dudley

[brokenrinker]

69ddbl - that's some pretty good bumbling. I've been looking around for months now and had found zero references to any other OEMs using Vision2000 windshields. Now if I can find a sympathetic ear at Baja Marine . . .

Thanks!