Sheet metal for dummies
Posted: Mon Aug 14, 2006 4:46 pm
Does anyone know of a tutorial for getting clean bends in sheet metal without the use of expensive equipment?
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Sheet metal for dummies
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Posted: Mon Aug 14, 2006 9:05 pm
Try lookin' at thebestcasescenario.com, I've found out a lot of info there. Even if they don't have a tutorial, you could probably find out by reading worklogs of modding projects.
Posted: Tue Aug 15, 2006 6:08 am
well....
1. get a couple lengths of say 1/2" x 2" alum. (6-10" longer than the part you want to make) and a pile of clamps. and a large cresant wrench, and a saw horse or bench vise.
2. file/grind a 1/8" or 1/4" rad down one edge of the flat.
3. clamp the sheet between 2 peices of flat having the one with the rounded corner where you want the bend.
4. clamp all that to the saw horse or in the vice, making sure that the hole thing stays in line where you want the bend.
5. push the sheet metal over a little at a time to get the disired angle.
you now have a poor mans break
or
get one of these or {url=http://www.harborfreight.com/cpi/ctaf/d ... mber=41311]these[/url]
now, to figure out how much metal you need to make you part, you need to make allowances for the bend it self, you might want to find a calculator.
for 90 deg bends for soft brass/copper
L=(0.55 x T) + (1.57 x R)
for 90 deg bends for half hard brass/copper, soft steel, and alum.
L=(0.64 x T) + (1.57 x R)
for 90 deg bends in bronze, hard copper, cold rolled steel, and spring steel.
L=(0.71 x T) + (1.57 x R).
L = the length of material need for just the bend.
T = thickness of the material
R = the radius of the bend you want. carefull not to go to small on the bend, too small and the sheet will crack. for most alum and steel under 3/16 (.1875) thick a 1/8 bend radius is doable.
ok now you have yourself a break, you have the right length of stock, build soemthing
I see if I can find a how-to on how to use the break.
1. get a couple lengths of say 1/2" x 2" alum. (6-10" longer than the part you want to make) and a pile of clamps. and a large cresant wrench, and a saw horse or bench vise.
2. file/grind a 1/8" or 1/4" rad down one edge of the flat.
3. clamp the sheet between 2 peices of flat having the one with the rounded corner where you want the bend.
4. clamp all that to the saw horse or in the vice, making sure that the hole thing stays in line where you want the bend.
5. push the sheet metal over a little at a time to get the disired angle.
you now have a poor mans break
or
get one of these or {url=http://www.harborfreight.com/cpi/ctaf/d ... mber=41311]these[/url]
now, to figure out how much metal you need to make you part, you need to make allowances for the bend it self, you might want to find a calculator.
for 90 deg bends for soft brass/copper
L=(0.55 x T) + (1.57 x R)
for 90 deg bends for half hard brass/copper, soft steel, and alum.
L=(0.64 x T) + (1.57 x R)
for 90 deg bends in bronze, hard copper, cold rolled steel, and spring steel.
L=(0.71 x T) + (1.57 x R).
L = the length of material need for just the bend.
T = thickness of the material
R = the radius of the bend you want. carefull not to go to small on the bend, too small and the sheet will crack. for most alum and steel under 3/16 (.1875) thick a 1/8 bend radius is doable.
ok now you have yourself a break, you have the right length of stock, build soemthing
I see if I can find a how-to on how to use the break.
Posted: Tue Aug 15, 2006 9:54 am
ok this took long enough to find 
http://www.taunton.com/finehomebuilding ... hvt058.asp
down on the right there is a link to a vid that shows how to make and use the poor mans sheet metal break. If you combine the steps in the vid with the store baought break you will 90deg bends and save on having to buy wood (wich isn't all that cheap any more)
http://www.taunton.com/finehomebuilding ... hvt058.asp
down on the right there is a link to a vid that shows how to make and use the poor mans sheet metal break. If you combine the steps in the vid with the store baought break you will 90deg bends and save on having to buy wood (wich isn't all that cheap any more)