File edges off and use gloves as required. Here is my trial fit of top and bottom - thankfully all good! If the exposed surface on a fascia or other trim profile is more than 8 in., create a rib to stiffen it. Use the combination square set perpendicular to the aluminum fascia and hold it against the underside. At the “nodes” of cuts and folds I drilled a 6mm hole. Align the siding's bend point with the hinged joint of the homemade brake. The TM10 is lightweight and portable and very easy to operate and maintain. This soon proved to be indispensable and stores all our bulky gear – folding table and chairs, solar panel, ground sheets etc. My plans were pretty simple. Whenever we had to bend aluminum we would anneal it first then bend and reheat treat, your best chance of not cracking it is in its softest most pliable state. It won’t make the centrefold of metalwork monthly, but it worked out way beyond my expectations will be perfect for what we want. I thought about drawing them up properly to post here but figured my “working drawings” give a much better idea of the level of detail that I planned/designed to!! I could get a 2.4m x 1.2m aluminium sheet for $90. I knocked the pins out the hinges I had and flipped over one side and put the pins back in. Step 2: Create Cuts in the Aluminum. Share it with us! Answer: 6061-T6 aluminum is tempered and notorious for not bending easily. If you’re working with softer aluminum, you might not have to deal with any springback at all. That’s the ideal, anyway, but the reality is that many parts arrive at the press brake in a less than ideal state. Tip: Use the vinyl strip on the front of the brake to gauge 3/4 inch, the hem is another 3/4 inch, so spacing from the end of the hem to the end of the vinyl strip yields the 1-1/2 inch needed. The metal should bend, but only bend it as far as it goes without forcing it. Most of the breaks you rent are 10'6" and do not work well with the prebent fascia cover since that stuff is 12' long. Bend up 90 degrees. I can confidently say that I expect to be a life-long subscriber." Aluminum also requires a calculation of the bend radius based on the thickness of the aluminum. It’s also easier to install than you might think. Use a ladder to reach the area where you will hang the fascia boards. The idea of adding an angle 5 degrees past 90 is so that you can bend past 90 to allow for the spring back. I then used a V bit in my router to make a 0.1 – 0.2 mm groove where I wanted to the folds to be to help encourage the aluminium fold in the right spot. Also, after each bending pass, work along with rubber mallet to sharpen the bend by bashing either side of the bend on the table edge. This has degraded over time (cracks, hinge broken) and needed replacing. Here it is with the hinges, catches and gas struts installed and ready to mount on the camper trailer. In our area in the Midwest, it is commonly available in 24 … After assembling a few of these pieces with some hinges, he was ready to bend some aluminum. Finished box is 2m long x 800 wide x 380 high and weighs 30 kg all up. Place one hand under the fascia and the other on the combination square. Use these tips to keep cables tight and straight for a professional-looking deck-railing job. The bend won't be quite as sharp, but suitable bends can be made for many construction projects without using a brake. Sheet aluminium can be cut without the need for a guillotine or tin-snips which tend to deform the metal. Lift the clamp bar away from the rear of the brake frame and slide the sheet in perpendicularly to the direction you want to bend it. So if I fold it up, and the sides are 200mm deep, that would make it 800mm wide – perfect. Grain direction- bend line should go across the grain for the best bend Having said that a typical sharp 90* bend on a piece of 1/8" aluminum sheet should be a minimum 1/8" inside radius, use either 3003 or 5052 & ideally the bend line should go across the grain. I allowed +3mm on the tabs that are to be folded as they overlap the sheet they fold over – hopefully the photos make more sense. The two M10 bolts in the top are to clamp the sheet between the backstop and the base. I guess that's what I'll end up doing. Use a saw or snips to cut the coiled siding to length. A motor mount. The drop sheet in the photo is there to help keep the noise down when hammering with the rubber mallet so I don’t disturb the neighbours too much. Click through to watch this … Be Aware of the Aluminum’s Grade. Once it is bent to around 45 degrees, move to floor where you can stand on the aluminium while you bend it - gives you more leverage and a tighter bend. Fig.2. If it is showing cracking or just plain fractures, anneal it where you will be bending it. Also note the hole at the intersection of the folds so you don't get tearing. For the purposes it is to be used for, I suspect some wood battens and some thin plywood sheet would be an easier build and probably cheaper. Flip the metal finished side up, slide the short leg into the brake, and bend another 90. on Step 9, Building Giant Articulated Hands (carved From Wood for Social Distancing), Route, cut and fold the bottom piece, Build the frame to go inside the bottom piece based on as-folded dimensions (luckily same as planned), Build top frame to match bottom frame (see sketch – inside dimension of top frame is same as bottom frame, Based on the outside dimensions of the top frame, work out top frame cuts/folds, Make top, fit frame then add hinges etc, 2 off 2.4 m x 1.2m x 1.6mm aluminium checker/tread plate - $90 each, 2 off 25mm x 25mm x 3mm wall x 3m long aluminium SHS - $25 each, 2 off 35mm x 15mm x 1,5mm wall x 3m long aluminium RHS - $17 each, Box of 1000 rivets – 4.8mm x 6.4mm - $20 – used around 300, 2 off Gas struts 535mm 200 N (20 kg) -$16.50 each, Bolts, nuts and washers for hinges and latches (had in stock – say $20), Table to work on (and enough space to work around! This is the table I used to fold the aluminium on – it is around 700 x 1300mm. Renting a brake is about 40 bucks and it's a hassle. Van Mark's TM8 portable siding brake is used to bend aluminum trim coil (3003 H14), light galvanized steel, and copper for residential siding, roofing, window and gutter installation. Rich bent this in under a minute. bending aluminium fascia without brake | Posted in Construction Techniques on July 24, 2002 05:40am I need to put five bends in a 10 ‘ length of aluminium fascia to match existing pieces. Place one hand under the fascia and the other on the combination square. Flip metal over, so that the finished side is down, bend 90 degrees. I then made the cut where appropriate with a jigsaw and fine blade. I also used some offcuts to make doubler plates where the hinges are to stiffen up the material a bit. Bends metal up to 18 in. Place the "fracture-line" over the edge of a table and bend the overhang SLIGHTLY downwards. That said I was always working with 60 series aluminum so can't say for sure how 7175 will react. This is the end product of the forming phase before inserting the frame and riveting, Here I am checking the overlap folds before riveting etc. I put nylon between hinges (galvanized) and aluminium to help reduce dissimilar metal corrosion. 2. The average hack requires at least one angled metal part, and the best tool to make one is still the good ol’ press brake. wide. Warning – the edges of the aluminium can be very sharp, particularly after it has been cut. Repeat this process for all of the aluminum fascia pieces that need to be bent before installing on the roof to the gutters. And 200 mm deep ends would make it 2m long – also perfect. The most simple way of doing this would be to use a MAP torch and heat it to the point where a mark from a sharpie dissappears. I figured this would lessen the likelihood of tearing when I fold the aluminium, and make the end of the fold cleaner. Existing box was about 400 deep. Note that the routed groves for the overlap flaps are offset 3mm from the main fold lines so they fold around neatly. These groves wound up pretty rough, but I think they helped. I made a "tool" from vice grips and a couple pieces of angle to get extra leverage and to help getting the bends. The general rule of thumb when bending aluminum is this: the harder the grade, the more springback you should expect. Finished product all mounted and ready to go. This video will show you how to do it, and hopefully save you some money! The question was, could I make 2m long folds in the aluminium? Here it is with the internal frame installed. It also can be used for any number of small projects that require bent light-gauge sheet metal or vinyl. Aluminum is the material that I bend most often. Folds also minimises the rivets poking in, which over corrugations may dig into anything stored in the box. Hearing protection is important when bashing! Aluminum comes in a variety of widths, colors, thicknesses, and finishes. Take a section of plywood, and clamp it down stationary. Nonetheless, by applying our old friend Mr. I placed a 25 x 25 angle along the bending edge to give a sharp edge to bend over and lessen the damage to the table when I pounded on the aluminium with the rubber hammer. So I thought about building my own. The bending brake’s design allows for a full 90º capacity in steel as thick as 16 gauge and can handle stock up to 18 in. And now I know it can be done without specialist equipment, so nice one. This is something I don’t discuss too often, bec… To do this, use a brake and gently bend the aluminum to avoid damaging it. I need to put five bends in a 10 ‘ length of aluminium fascia to match existing pieces. I bend it to make flashing, fascia, and many other profiles, including window cap and door trim. wide; Handles material as thick as 16 gauge; Makes bends to 90º; Easily clamps or mounts to workbench Line the aluminum piece up with the combination square in a straight edge and measure in about an inch. Most frequently, expensive sheet metal bending tools, called brakes, are used to bend sheet metal, but you can also complete this task without one. From a bending perspective, it’s always best to bend these parts in an annealed state and then temper them to the correct condition. - M.K. With the show side up, make about a 30-degree bend. Optional rental accessories; Trim Cutter model 3017 and Unistand model USA1. Many builders would be happy to bend it for you for a small fee. Plan was to fold and rivet as I don’t have an aluminium welder and did not want to build a frame and rivet sides to it. The normal rule-of-thumb is the bend radius for aluminum should be 3-5 times the thickness of the metal; this requires the use of a nose bar equivalent to: .064” to .096”. The brake is compact and lightweight yet sturdy enough for professional production runs. There are many ways to get the job done without having all of the tools. Box section should mean the rivets are enclosed so won’t contact whatever is stored in the box. This material is inexpensive, easy to cut and bend, and the factory finish lasts for many decades without deterioration. This will give you a nice bend. Overall, I’m stoked at how it has worked out – I was taking a shot in the dark here if I would even be able to bend the aluminium in a straight line. How to Install Cable Rail Around Wood-Post Corners, Interior Finishes for a Cabin in the Woods, Plus, get an extra 20% off with code GIFT20, Simple Way to Make Old Walls Straight and Plumb, Expert insights on techniques and principles. 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