Like other metals, aluminum has many advantages over wood in that it does not warp, rot, mildew, split, splinter, or crack. No knots detract from its perfectly uniform cross section. It already has a beautiful, naturally attractive surface that is smooth and satiny. So many projects require no surface finishing at all.

Aluminum, however, is not a single metal but a whole family of metals. There are many different aluminum alloys, each available in several different tempers. Thus aluminum is made in hardnesses ranging from material nearly as soft as lead to material much harder and stronger than structural steel.

The manufacturer of "Do-It-Yourself Aluminum" selected and engineered a particular alloy and temper so that ordinary woodworking tools can handle this aluminum without any damage to the tools. It is especially suitable for use in home workshops. Leading manufacturers of hand and power tools have tested and approved it.

Figure 1-1 shows the basic forms of Do-It-Yourself Aluminum. More than 11,000 hardware stores, lumberyards, and building-supply outlets all over the country display it in special racks (Fig. 1-2).

Fig. 1-1.

Every piece of this aluminum carries a Do-It-Yourself Aluminum identification sticker. See Chap. 15 for cost data. The various forms of Do-It-Yourself Aluminum available include the following items:

Sheet comes with a plain smooth surface, or embossed or perforated in several different designs. All sheet measures 36" x 36" and is a single thickness (0.020") except for certain perforated patterns which are 0.025" as noted below.

Embossed Sheet is made in three different patterns .... leather grain (Fig. 1-3), wood grain (Fig. 1—4), and the square pattern (Fig. 1-5).

Fig. 1-2.

Fig. 1-3.

Fig. 1-4.

Fig. 1-5.

Perforated Sheet is available in four patterns .... cloverleaf perforations in stucco-embossed aluminum 0.025" thick with 49 per cent of its area open (Fig. 1-6), round-hole perforations in plain sheet with 12 per cent open area (Fig. 1-7), lincane perforations in plain sheet with 43 per cent free air space (Fig. 1-8), and union jack perforations in plain sheet 0.025" thick with 40 per cent open area (Fig. 1-9).

* Reynolds Metals Co., Louisville 1. Kentucky.

† Delta, Dission, Black & Decker, Stanley, De Walt, Skil Corp., and others.

Fig. 1-6.

Fig. 1-7.

Bar Stock is in two sizes .... 1/8" x 3/4" and 1/4" x 1". Six-foot lengths are standard, but eight-foot lengths are also available on order if your dealer does not stock them.

Angle

Two sizes . . . . 3/4" x 3/4" x 1/8" and 1" x 1" x 1/16" .... 6' and 8' lengths as above.

Tube

Three sizes .... 3/4" outside diameter by 0.049" wall thickness, 1" O.D. x 0.049", and 11/4" O.D. x 0.058" . . . . 6' and 8' lengths as above. Spring-actuated snap-in end plugs and locking-type flanges (Fig. 1-10) and other fittings are available for each size tube.

Rod is a single size, 3/8" diameter. It is available in both 6' and 8' lengths.

In addition to the above standard shapes, several special sections are carried to facilitate construction of window screens and storm sash.

Fig. 1-8.

Fig. 1-9.

Window Screen Sections include a special framing section for use with the plastic spline, another frame section for use with the aluminum spline, and various brace or cross members, along with drive-in clips and locks for connecting both types of frame members at the corners, as well as hangers, hooks, and eyes for mounting screens. All sections are made in both 6' and 8' lengths.

Clear Plastic Film used with the above screen sections to make storm windows comes in roll form 36" wide and 0.004" thick.

Storm Sash

The extruded section for making glass storm windows comes in 5',

6', and 8' lengths to assure minimum loss in fitting to windows. Corner braces, hangers, and accessory hardware are in kit form.

Trim Strip, 5/8" x 0.025" x 6', is a decorative strip used for edging tables and wall panels.

Fasteners

To join these aluminum members, the Do-It-Yourself racks (Fig. 1-2) carry a wide assortment of aluminum fasteners, including round-head machine screws and bolts in five sizes . . . . 8-32 x 10-24 x 1/2" and 1/4"-20 in 1" and 11/2" lengths; panhead sheet-metal self-tapping screws .... #6 in 3/8" and 1/2", #8 in 3/4" and 1"; brazierhead rivets----3/32" x ;1/8" x and 1/8" x 3/4".

Fig. 1-11.

Accessory Kits group various accessory items, such as for mounting screens (Fig. 1—11), or the corner braces, screws, and associated items required to build and mount storm sash.