I made this bracket to hold the throttle assembly on the front of a 928S engine after the mechanical fan assembly had been removed. The bracket is made from two pieces of 6061 aluminum - one piece roughly 4"x5"x1/2" and one piece roughly 2"x4"x1/2". After being machined I welded the two pieces together and added a gusset made from 1/8" aluminim.

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This was my first attempt at machining the back plate. Unfortunately I turned the wrong handle on the mill and moved the Y axis instead of the Rotary table and managed to flatten half of the lower boss. :/
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I didn't have any appropriate t-bolts for the rotary table so I welded some from some steel stock and some M10 bolts.
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Here's the piece of aluminum after being cut on the bandsaw. I also drilled out the two upper holes before starting to machine. The piece is clamped to my rotary table.
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I used a Sharpie magic marker to scribe the outline because I don't have a real scribe.
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Here's the initial triangle cut out on the Mill. I didn't do the bottom corner on the mill because it was quicker to just sand it down.
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The piece has been roughed out and the two heights are set. The clamping method here is a little awkward because I don't have three of the correct sized clamps and one of my t-bolts is too short.
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Everything up to this point was done with a 1" 6-flute cutter. For the rest of the work I switch to a 3/8" 4-flut cutter.
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Here's the backplate mostly finished, although I clean up the upper arches a bit better later on.
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Here's the upper arches cleaned up and the pieces has been polished on my buffer.
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The Jet belt sander is indispensible! I had no idea how much use I'd get out of it before I got it!
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Unfortunately I didn't take any pictures of the front piece as I was making it. Here the two pieces are welded together and I'm about to machine on side of the weld down to clear the bolt.
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This picture shows the inside weld seam before I added the gusset.
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The gusset is welded on. I welded both sides of the gusset and then machined the top side down just for looks.
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You never know when you'll need a big hammer.
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Here's the completed bracket, polished and ready to go!
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Text, photography and layout by C.S. Mo
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