Author Topic: "How to" ? Mount aluminum nerf bars to 85 RC Frame ??  (Read 1928 times)

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Offline EDDIEK

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"How to" ? Mount aluminum nerf bars to 85 RC Frame ??
« on: September 1, 2018, 10:46:57 pm »
Searching for the best method to attach aluminum nerf bars (3 in round Zee Dee) to frame of 85 RC ??
I understand a little, enough to know that you should not bolt or weld aluminum to the steel,..
 per google search :::    "This is called galvanic corrosion. When you join aluminum and steel together, the aluminum will be preferentially corroded. ... Use an isolating coating or paint on the aluminum and the steel to isolate them electrically. However, all of your effort will go for nothing if you just bolt the joint together.Nov 19, 2014" 
Anyone who has done this, please advise..   TY.. Ed   

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    Offline dodge82273

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    Re: "How to" ? Mount aluminum nerf bars to 85 RC Frame ??
    « Reply #1 on: September 2, 2018, 01:42:19 am »
    there are different grades of aluminum , the softer grades degrade much faster ... Any connection of the 2 dissimilar metals will cause the corrosion , and IF something like salt water is added it dramatically speeds the process . you could use a glue , epoxy them on ,  same way new autos are assembled .... otherwise IDK ... but the corrosion will be right AT the connection , NOT the whole surface of the bars , so it may last a while looking good ..
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    Offline jungle

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    Re: "How to" ? Mount aluminum nerf bars to 85 RC Frame ??
    « Reply #2 on: September 2, 2018, 03:57:05 am »
    Can they be bolted to the frame with a gasket between the two different metals?
    Jim
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    Offline Elwenil

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    Re: "How to" ? Mount aluminum nerf bars to 85 RC Frame ??
    « Reply #3 on: September 2, 2018, 07:13:14 am »
    Yes, with a gasket it will be fine. There is actually a tape used for this purpose used in the RV industry, but I forget the name. Just about anything that will last should be fine, though.
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    Offline flyfish

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    Re: "How to" ? Mount aluminum nerf bars to 85 RC Frame ??
    « Reply #4 on: September 2, 2018, 07:58:24 pm »
    one of those "plastic" cutting boards that's used in the kitchen that's roughly 1/4" thick maybe a little less comes to mind...that is if nothing else is laying around the house/garage that could be used. Draw out a stencil and cut your shape
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    Offline Elwenil

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    L.Clemons

    1988 Ramcharger AW450-318EFI-NP435 4 speed-NP205 Transfer Case-Dana 60s-Braden Wormdrive Front Winch

    2018 Ram 2500HD Crew Cab 4WD 5.7L

    I am the unknown Will,
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    Offline EDDIEK

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    Re: "How to" ? Mount aluminum nerf bars to 85 RC Frame ??
    « Reply #6 on: September 2, 2018, 11:22:45 pm »
    dodge82273
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    flyfish

     Thank you all for your kind attention to my question. I poured over the internet, at least you can pretty much exhaust what there is "information wise" out there if you spend a few hours and use the correct search terms etc etc..  It seems that the most people who deal with joining two "dissimiliar metals" are people who build trailers and other tow able wheeled vehicles and pleasure craft boat builders. Both are concerned with weight and often use aluminum but still need to adapt existing vehicle axles which are steel, etc etc..  The boat guys stress to use the same type of metal e.g. aluminum rivets (never steel) when fastening two pieces of aluminum, say for a boat dash gauge cluster. I will  add..  links to the various articles that I found useful, to begin to understand how to approach this project. It's going to be a couple of months ... as I am finishing up hand wiring my entire RC.. part of which had to do with finding a digital voltmeter.... to partially compensate for the problematic ammeter gauge.  I thought that I was just going to have a welding shop weld the 3 in round black step bar.. (Nerf Bars) to the frame under each door to the cab. Basically what I have concluded is that.
     
    (1) the mounting flange onto which each side of the step bar will bolt to, must be insulated from the frame.
    (2) Yes a good coat of paint to each surface is a must, (but alone it's no where near sufficient) in addition to sandwiching an insulator, a non conductor such as a piece of rubber, or sheet of rigid fiberglass between the frame and the mounting bracket / pad..
    (3) The use of galvanized / zinc coated carriage bolts are required, BUT where they pass through the other side of the frame, they must be insulated from contact with the aluminum mounting bracket / pad as they protrude through the mounting holes. Some use nylon sleeves. I am thinking that sections of small PVC pipe may work, or small nylon bushings, found in those pull out drawers of fasteners at the home improvement stores.
    4) Not to mention a nylon washer to insulate the nut that will be tightened down the threads of the mounting bolt up against the face of the mounting bracket / pad. 
    There may be a (5) and a (6) to this assembly.  You would think that someone would have fleshed all of this out ? How many trucks have aluminum frames ???  I will call the step bar manufacturer to see if they have a mounting kit, to save time and trial and error.  Had I known re galvanic corrosion, I may have had some 3 in round steel bars bent and just welded to the frame !!!!  The above is incomplete, anyone wanting to do this double check their own research.. This is load bearing stuff vs cosmetics... 

    I forgot a major item, moisture, even humidity etc is the link between the two metals, it carries the current !!!   

    P.S. That plastic cutting board idea is spot on, the wife got one from bed bath and beyond ....heh heh heh.....

        https://galvanizeit.org/education-and-resources/resources/technical-faq-dr-galv/using-paint-as-an-electrical-insulator-in-dissimilar-metals

       https://www.google.com/search?q=how+to+prevent+galvanic+corrosion+between+aluminum+and+steel&sa=X&ved=0ahUKEwiIh-Kfs5vdAhUPhuAKHThEDuMQ1QIIugEoAg&biw=1600&bih=743

    https://www.hunker.com/12502151/screws-compatible-with-aluminum

    https://www.westmarine.com/buy/tef-gel--corrosion-eliminator-and-anti-seize-lubricant-tube-with-applicator-20cc--12222212?recordNum=1

    https://www.eng-tips.com/viewthread.cfm?qid=94941

    https://www.albanycountyfasteners.com/Carriage-Bolts-and-Timber-Bolts-s/281.htm
         
    « Last Edit: September 3, 2018, 12:41:26 pm by EDDIEK »

    Offline dodge82273

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    Re: "How to" ? Mount aluminum nerf bars to 85 RC Frame ??
    « Reply #7 on: September 3, 2018, 01:18:16 am »
    you are correct in that the nuts/bolts need to be isolated as well as the mounting surfaces . seems like alot of hassle for a "it may work " thing , I'd just bolt them on , they "should" last a few YEARS , at whick time you'll either want something else , or ....       I bought a truck with aluminum running boards , extruded type , they are fastened to the fenders opening with self tapping screws ... they are NOT corroding ... ??? 
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    86-D/W100 44/corp/318mag/carb/4500/aka shit box/winter
    93w150short/44/corp/360/le/mag "caddie"
    93w250LB51844/60posi 318"New Truck"
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    Offline flyfish

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    Re: "How to" ? Mount aluminum nerf bars to 85 RC Frame ??
    « Reply #8 on: September 3, 2018, 08:52:09 am »
    We've got probably 7 of those cutting boards and I was thinking just the other day..."why the hell do we need 7 cutting boards"...that's what made me think of it LOL-and the material is really tough. Problem is my wife thinks she needs all 7 :).   I have a thrift store close to home with all sorts of things I like to find problem solving pieces like this. A cutting board there might cost a dollar.

     
    P.S. That plastic cutting board idea is spot on, the wife got one from bed bath and beyond ....heh heh heh.....
       

    I'm glad I read your thread...now I'm thinking I will employ some of these ideas for installing my aluminum fuel tank. It probably does take awhile for corrosion of steel to aluminum to take place but with all that weight of fuel shifting around, a little corrosion might lead to a failure. IF you're lucky to have one near you, Ace hardware has a better selection of all those bushings, sleeves, etc than the big box stores like HD lowes, etc.
    « Last Edit: September 3, 2018, 09:08:56 am by flyfish »
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    Offline EDDIEK

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    Re: "How to" ? Mount aluminum nerf bars to 85 RC Frame ??
    « Reply #9 on: September 3, 2018, 12:51:35 pm »
      Here is a good article re basics re galvanic corrosion...

      https://galvanizeit.org/education-and-resources/resources/technical-faq-dr-galv/using-paint-as-an-electrical-insulator-in-dissimilar-metals

        It seems to me that using zinc / galvanized nuts and bolts solves 98% of the problem because of the thickness of that coating engineered into the nuts and bolts..  I also read  in one of those linked articles.. that if you weld the aluminum to the steel frame, the joint between the two becomes some kind of brittle combination of the two, prone to failure. So welding these step bar onto the frame is out of the question.   Ed

     

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