I have a large robot made out of wood. The robot is 4 feet tall and 2 feet wide and 2 feet long. The robot's structure is fine with just the wood however I am looking to cover the wood with some type of material preferably some thin metal like sheet metal. I am planning on needing 50 square feet of the material. I am open to using other substances such as plastic. I am trying to do this for about 100 US dollars. What options do I have? I know I can use some really thin metal but I know it is a lot of money for this.
Too bad you need so many sq ft. Joe Barker wrote a book on making models from soda and beer can metal.
Don't laugh too hard, can metal is plated to make the labels stand out. Some cans like Coors are highly shiny silver and some cans have a gold-color plating. The book covers recovering metal from the cans, removing the painted label and aspects of joins and all. The results just look fantastic. Check that bottom model; http://www.fiddlersgreen.net/other/WSAM-Explained/sodacans/sodacans.htm
If you can find a company that does sheet metal work, you might be able to buy sheets or rolls from them. The more they buy on an order, the better the price they get. An honest shop will charge a 10%-15% markup but even double is still way better than retail.
Shop around. Check places that do duct work. Maybe they can put bends and holes in for you, at a price but they have tools for that though what tolerances they'll hold are more house building than cabinetry. Good luck finding a shop that does that any more and better luck being able to afford their rate if you do! Sorry, but I was in that business once and the work dried up long ago.
You could maybe fiberglass the wood instead? It would become way stronger. Or even replace the wood with glass over foam, a monocoque shell body like a custom aircraft?
Warning; learning curve involved, I've seen some "just do it" overweight messes that just looked hairy. My old rocket-buff neighbor told me about squeezing the excess resin out but not wanting to lose too much, but he was going for extra light and strong on 4" tubes.
120$ if I go with the sheet metal. only 50$ if I go with the flashing. Will flashing tear? is it more like aluminum foil or sheet metal? I just don't want it to tear if the robot happens to scrape a wall.
arduinoPi:
120$ if I go with the sheet metal. only 50$ if I go with the flashing. Will flashing tear? is it more like aluminum foil or sheet metal? I just don't want it to tear if the robot happens to scrape a wall.
Flashing is not like aluminum foil, but more like sheet metal. Go to lowes or Home Depot and check it out. As to protecting the wood, caulking and a good coating like outside paint or spar varnish might also be in order.
edit: also check in the heating section of the same stores for thin galvanized steel sheet metal.
used offset printing plates. Find a large printing company that has an offset printing press, the plates are thin aluminum that are etched to hold ink. the inside surface is generally pretty clean and yu can get the plates for salvage value, or free with a good story.
I just don't want it to tear if the robot happens to scrape a wall.
That's what duct tape's for.....
Does it have to be metal?- what about that sticky plastic stuff for covering kitchen shelves or school books? I don't know the brand-names or prices though.
THAT is a brilliant idea. I once got some to use to make a solar oven thingy... a colleague picked them up at a client, those particular ones were A1 size iirc. They are dead simple to work with, bend easily along a piece of timber, easy to cut with a pair of scissors. Just beware of very sharp edges....
arduinoPi:
The function of the metal would be for aesthetic reasons as well as keeping the wood safe from dirt or water.
In that case I don't think that simply attaching metal panels will give the wood much protection - if there's water about, it might actually make things worse by holding water against the wood, as well as corroding itself.
I suggest you start by filling, sanding, priming and painting the wood - on any surfaces that need protection, not just the external ones. You can get shiny metallic paint that looks similar to polished metal but much easier to apply and without you having to deal with accurate fitting and corners and joints and so on. If you're concerned about impact damage, fit bumpers.
i would suggest fiberglass just make sure to get as much excess resin out as you can then sand smooth from 200 to 1000 grit for a nice smooth surface then a few coats of high gloss black then 2x more coats of high gloss polyurethane
The litho-plate solution is the most recycly one - and you get the choice of the metal side or
the litho-coated side (I've had some in the past that was coloured green - perhaps this is
standard?)
