Transom cap material?

[reelfishin]

This has been brought up before, but I figured I'd see if anyone has any new ideas.
I'm in the process of redoing several transoms, one a Starcraft SS, for which its thin aluminum transom cap is no longer usable, and two other smaller boats, also both aluminum.
For the one, I'm raising the transom height 5", and the original transom cap, although corroded away in the middle, is no longer going to fit.

Does anyone know of a company making a universal extrusion or sheet metal part that could be made to work? I've taken aluminum tubing and rip sawed it to get what I need before but that's a lot of work and is often too thick. What I need is the equivalent of 1.55" ID C channel bent out of .080" or so aluminum, with about a 1/2" lip on both sides. So far I can't seem to find anyone that can form this shape in a brake or press.

I would think that with all of those that rebuilt boats, there would be something available?

 

[hump07]

Re: Transom cap material?

I used plastic roofing drip edge on my ss

 

[reelfishin]

Re: Transom cap material?

I used plastic roofing drip edge on my ss

I can't picture that stuff being heavy duty enough to really protect the edge of the transom?

On mine, I now have the transom wood completely encased in fiberglass, as well as laminated together in the middle with a layer of epoxy and glass mat. The transom will no doubt out last all of us. I used ABX grade exterior grade ply which I planed down to 11/16" so that I end up with the right thickness transom when all is done. What I have now is a raw aluminum edge, and the semi rounded edges of the new transom wood covered in glass. The rear edge of the transom is rounded and about 60" long or more, I thought about just filling it in with epoxy but would rather just cap the whole joint as the OEM did. It's as much about a finished appearance as it is protecting the new transom.
I run into this quite often, while some boats can be done with polished aluminum angle miter cut and sealed, an aluminum boat needs a real cap installed. If it were straight, I'd just bend up a cap on a sheet metal brake but these need to be curved and pretty stout to handle wear and tear from a larger motor.