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Old 10-26-2014, 08:29 PM   #1
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Fabricating brackets for Aluminess Ladder

.....or what I did to my van today........

The stock Aluminess ladder mounting brackets weren't doing it for me, so I decided to fab some up.

I'm hoping that these will be easier on the rain gutters and more robust. The two tiny screws digging into the rain gutter sealant on the stock clamps were bugging me, and the workmanship left something to be desired (the PEM studs were at crazy angles as were the small tapped clamping screws; nothing was perpendicular.

The plan is to use #10-32 nylon-tipped set screws to clamp these to the rain gutters......the set screws screw in on the underside of the rain gutter facing up. I also threaded the brackets to accept screws through the ladder (without nuts). I went down one size on the hardware (on the bottom as well) to #10-32. The 1/4-20 stuff seems overkill, even if you are a 300 pounder.

I bead-blasted and rattle-can painted them for now; when I get enough aluminum stuff fabbed up I'll take a batch to the powder coaters.

They are in the garage drying (wet paint) presently; I'll post a few more pics when they are fully baked.
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ladder brackets 3.JPG   ladder brackets.JPG   ladder brackets 2.JPG  
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Old 10-26-2014, 08:35 PM   #2
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Re: Fabricating brackets for Aluminess Ladder

Very nice. I've got a CCV ladder, basically just like an Aluminess, and have been pretty unhappy with that as well. Somebody oughta make these and sell them!

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Old 10-27-2014, 05:50 AM   #3
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Re: Fabricating brackets for Aluminess Ladder

Exceptionally nice pieces Scotty---you're now in competition with MGMetalworks!

There were milled from bar stock I take it? CNC machine?

What I like most is their close fit to the rain gutters and how they spread the load over a wider area. That should make these a lot less stressful on the sealant and the roof joint too.
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Old 10-27-2014, 08:04 AM   #4
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Re: Fabricating brackets for Aluminess Ladder

Sometimes you guys just really piss me off with your bad-a$$ skills! Great job.

-John
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Old 10-27-2014, 08:28 AM   #5
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Re: Fabricating brackets for Aluminess Ladder

Quote:
Originally Posted by JWA
There were milled from bar stock I take it? CNC machine?
yes, 6061-T6 that i had laying around. Bridgeport. A few more pics to come......
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Old 10-27-2014, 09:54 AM   #6
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Re: Fabricating brackets for Aluminess Ladder

Quote:
Originally Posted by JWA
Exceptionally nice pieces Scotty---you're now in competition with MGMetalworks!

There were milled from bar stock I take it? CNC machine?

What I like most is their close fit to the rain gutters and how they spread the load over a wider area. That should make these a lot less stressful on the sealant and the roof joint too.
JWA, Boywonder made these, not me! They sure are pretty though. I have no skills like that.

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Old 10-27-2014, 11:33 AM   #7
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Re: Fabricating brackets for Aluminess Ladder

OK, now I am really jealous. I now realize that asking you to source a non-ferrous mitre saw blade must have been viewed as pretty weak on my part.* I just looked up the Bridgeport Milling Machine on my local craigslist. There is one for $2850 which is out of reach right now. Your brackets are artwork and likely what the designer intended until the production people said "Hey can't we do the same thing with a couple of machine screws (which will likely scratch the paint causing a rusted rain gutter and will not distribute the load as well...)?

I have moved through the wood age, to the steel age, but have yet to evolve to the aluminum age.
So, in comparison, my knuckles are still dragging...

(I do, however, consider my polyester and also epoxy fiberglass skills to constitute a separate but parallel evolutionary lineage.**)


*But if not, is the same blade available in 10" with a 1" arbor for my table saw?!
**You're down that way so be sure to check with Gigi or Wade at Fiberglass Hawaii, Ventura, for your fiberglass needs. They also ship.
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Old 10-27-2014, 05:32 PM   #8
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Re: Fabricating brackets for Aluminess Ladder

Those look great! If you get enough demand for them, you could extrude that profile and have fewer machining operations.
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Old 10-27-2014, 07:27 PM   #9
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Re: Fabricating brackets for Aluminess Ladder

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Originally Posted by mgmetalworks
Those look great! If you get enough demand for them, you could extrude that profile and have fewer machining operations.

......exactly what Aluminess should do.......but I suppose that they have a some really good welders.......

These parts scream "extrude me"!!
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Old 10-27-2014, 11:16 PM   #10
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Re: Fabricating brackets for Aluminess Ladder

Wow! Those are nice. I had exactly the same thoughts when I saw the stock Aluminess attachment. But unfortunately I have none of those skills. Let me know if you do go into production, seems like there's a market for your work.
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