Metalwork for RC Hobbyists: A Practical Buying Guide for Aluminium, Steel and Brackets

Metalwork for RC Hobbyists: A Practical Buying Guide for Aluminium, Steel and Brackets

Picking the right metal for an RC project can make the difference between a light, responsive model and one that is sluggish or fragile under load. This guide focuses on what to buy and why, with emphasis on aluminium, steel, brackets and techniques for building lightweight but durable structures. It is aimed at hobbyists who want practical advice rather than academic detail.

Start by understanding the two most common metals you will encounter: aluminium and steel. Aluminium is light, corrosion resistant and easy to machine or cut, which makes it the default choice for frames, skins and many brackets. Steel offers greater stiffness and toughness per unit thickness, which suits high-stress components such as motor mounts, suspension parts and reinforced brackets. Stainless steel resists rust well but is heavier, while mild steel is cheap and weldable but needs protection from corrosion.

Not all aluminium is the same, so pay attention to alloy and temper when buying sheet, plate or tube. 6061 is a good all-round alloy that machines well and is readily available in sheet and extrusion form, while 7075 is stronger and often used where every gram of strength matters, at a higher cost and with poorer weldability. Common forms are sheet (0.5mm to 6mm for hobby use), tube (round, square, rectangular) and extrusion profiles for rails and frames. If weight is critical, favour thinner sheet and thoughtful structure rather than thinner material alone, and consider anodised finishes for wear resistance and aesthetics.

Brackets and fittings are where steel often earns its place in an RC build, because simple welded or riveted steel brackets can carry high loads without bulk. Off-the-shelf L-brackets, gussets and angle irons are convenient and inexpensive, but custom laser-cut or CNC-machined brackets give a cleaner fit and can save weight by removing excess material. For fasteners, small models typically use M2 and M3 hardware, while larger scales move to M4 and up, and clever use of rivet nuts or tapped standoffs can avoid weak sheet threads. Remember that each joint choice influences ease of maintenance and repair as well as initial strength.

Designing lightweight structures is about geometry as much as material choice, and methods like triangulation, ribs and bonded sandwich panels let you use softer materials without sacrificing stiffness. Use gussets at corners, distribute loads through multiple attachments and avoid long unsupported spans that can flex under vibrational fatigue. Adhesives and structural epoxies are excellent for aluminium if surfaces are prepared, but mechanical fasteners add servicability and predictable failure modes, which is important for safety-critical parts. For build examples and supplier links see WatDaFeck.

When you go shopping, bring a checklist: decide the forms you need (sheet, tube, angle, extrusion), specify thickness ranges and alloys, and note finish requirements such as anodising or galvanising. Typical thicknesses for RC components are 1.0–2.0mm for aeroplane skins and lightweight chassis plates, 1.5–3.0mm for strength-critical plates and brackets, and 2.0–4.0mm or thicker where welding or high loads are involved. Invest in a few essential tools such as quality metal drill bits, taps, a deburring tool, and a bandsaw or metal-cutting jigsaw blade for accurate cuts. Lastly, finish edges and protect exposed steel to prevent corrosion and to reduce the chance of cuts during maintenance.

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