The Strength Beneath the Surface: Anodizing Aluminum for Tolerance Stack Mounting Systems
- Services @ TS
- May 19
- 3 min read
Updated: May 20
At Tolerance Stack, we're committed to providing not only robust and precise mounting solutions to attach the scheel-mann Vario F to your vehicle, but also components with exceptional durability and a lasting finish. A key element in achieving this is the anodizing process we utilize for our mounting system side panels.
What is Anodizing?
Anodizing is an electrochemical process that converts the outer layer of aluminum into a durable, corrosion-resistant, anodic oxide finish. Unlike paint, Cerakote or powder coating, which simply apply a layer on the surface (with varying thicknesses to accommodate for), anodizing is a controlled oxidation process that integrates with the underlying aluminum, resulting in an incredibly strong and long-lasting finish. The anodic layer is typically much thicker and harder than the naturally occurring oxide layer on aluminum.
The General Anodizing Process:
While variations exist, the basic steps in anodizing aluminum are:
Cleaning: The aluminum part is thoroughly cleaned to remove any dirt, grease, or other contaminants. This ensures a uniform anodized layer.
Etching (Optional): Sometimes, a chemical etch is used to create a matte or textured surface.
Desmutting: This step removes any residue ("smut") left from the etching process.
Anodizing: The aluminum part is immersed in an electrolytic bath (typically an acid solution, such as sulfuric acid) and serves as the anode (positive electrode). An electric current is passed through the solution, causing a layer of aluminum oxide to form on the surface of the aluminum. The process is carefully controlled to achieve the desired thickness and properties of the anodic layer. The images above and below show a typical anodizing setup with multiple tanks for the various stages.
Coloring (Optional): If a colored finish is desired, the porous anodic layer can be dyed with various pigments. The facility we use does only black and clear. "Clear" gives a uniform matted look to the finished part with no colored dye added. If you are a fan of cool looking CNC machining marks then doing Clear anodize hides that in it's anodic layer.
Sealing: The final step involves sealing the porous anodic layer to prevent corrosion and improve wear resistance. This is often done by immersing the part in boiling de-ionized water or a chemical sealant.
Tolerance Stack's Anodizing Process: Strength and Style
Our process for anodizing the side panels (and rear mounting brackets, for the Tacoma and FJ Cruiser) of our mounting systems is carefully tailored to ensure the highest quality and durability.
Material and Fabrication: We start with either 1/8" formed or 3/16" thick flat aluminum sheet. This provides a strong and stable base for our side panels. The aluminum is then laser-cut to the precise dimensions required for our designs and tumbled to remove sharp edges and create a smooth surface.
Fiber Laser Engraving: Before anodizing, we use a fiber laser to engrave the Tolerance Stack logo onto the side panels. This creates a permanent and aesthetically pleasing mark that showcases our brand. The logo, as seen below, is precisely engraved into the aluminum. The logo is angled to visually sit parallel with the vehicle's door sill.
Anodizing: The laser-engraved aluminum parts then undergo the anodizing process, following a similar procedure to the general steps outlined above. This creates a hard, durable, and corrosion-resistant finish that protects the aluminum and enhances its appearance.
Sealing: The anodized parts are then sealed, ensuring a long-lasting finish that can withstand the rigors of automotive use.
The result is a mounting system side panel that is not only strong and precisely engineered but also boasts a durable and attractive finish, thanks to the anodizing process.
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