Titanium flat shapes.

This week I replicated 2 parts for the Mini engine bay that could do with a lighter corrosion proof version. They are the bulkhead plate with one hole for heater hose and the alternator adjusting bracket.

I took the original parts off my Mini and couldn’t believe how corroded the blanking plate was. I suppose it has been slowly rusting away since 1986 and the bulkhead is a water trap.

Scanned the parts in to the PC and put into Solid Works. Modelled around the picture of the original parts, paying close attention to the measurements.

Took the Solid Works file and the titanium to an engineer shop in Redditch. It was amazing! Machines the size of houses. The chap put the files into his PC and we walked across the factory to the water cutter.

I wish I could’ve taken a photo of this machine. It’s massive! Like a shallow bath with a big moving girder holding the hoses. Lay the metal on the machine, the chap pressed some buttons and the machine was away. Firing water and abrasive at 60,000psi. The parts were cut and vibrated to deburr any rough edges. They are also accurate.

Here's the finished result

Rusty steel bulkhead plate = 60grammes

Titanium bulkhead plate = 35.9grammes

weight saving of = 24.1grammes

Rusty steel alternator adjusting bracket = 50grammes

Titanium alternator adjusting bracket = 36.5grammes

Weight saving of = 13.5 grammes

Not a massive weight saving with this part but if you notice it's 4mm titanium, 1mm thicker than the steel item, so you'll get the extra strength as well as a weight saving and corrosion proof.

Grade 1 and 2 titanium doesn't polish up as well as stainless steel but you'll never get those little rust spots you'll get on stainless. Yes, stainless steel rusts. It just takes longer.

I'll put these titanium items on sale within a week. I think I have 18 alternator adjusters and about 9 bulkhead blanking plates. They're unpolished but respond quite well to polishing. You'll never get them as shiny as stainless though.