Sometimes called a siding brake or an aluminum brake, this tool can be used for cutting and bending flashing for windows and doors, and for cladding for exterior soffits and fascias. Become a member and get instant access to thousands of videos, how-tos, tool reviews, and design features. The greater the bend radius, the less of an issue it will be. Move slowly along the fold, doing 10 – 20 degree bends at a time. Weight was as an issue, so I thought of aluminium. The structure of the roller-type mark-free die is shown in Fig. Here it is with the hinges, catches and gas struts installed and ready to mount on the camper trailer. Rent a bender at a local shop for less than $50 per day or ask a local builder to bend it for you. Did you make this project? Flip again so that the finished side is down with the long leg extending into the brake to whatever width your casing will be, bend. 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. 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. 2 years ago Box section should mean the rivets are enclosed so won’t contact whatever is stored in the box. 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. Renting a brake is about 40 bucks and it's a hassle. Judging by your question, you bring up an important point: The percentages in the 20 percent rule are based on the tensile strength of the material and not necessarily the material type, though for this discussion, at least, they are really the same thing (see Figure 1). Mathematics, we can achieve extreme accuracy with our calculations. So I thought about building my own. Existing box was about 400 deep. File edges off and use gloves as required. Warning – the edges of the aluminium can be very sharp, particularly after it has been cut. The metal should bend, but only bend it as far as it goes without forcing it. Get complete site access to expert advice, how-to videos, Code Check, and more, plus the print magazine. Due to the size of stuff stored, I was limited on what size box I could get as a replacement – it had to fit the table (930 x 750 mm) and the solar panel (1200 x 700mm) – so that set the minimum width and length. From a bending perspective, it’s always best to bend these parts in an annealed state and then temper them to the correct condition. 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. I laid the sheet out on my table and measured it out and marked it with a felt marker. Use a ladder to reach the area where you will hang the fascia boards. "I have learned so much thanks to the searchable articles on the FHB website. Photo of the finished folded corners all riveted etc. 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. This video will show you how to do it, and hopefully save you some money! Bending parts re… Remove the sheet, flip it around, still finished side down and hem the other end. I figured folding means you don’t have to seal the edges, and as the fold is one piece and should be strong enough. Move slowly along the fold, doing 10 – 20 degree bends at a time. I then made the cut where appropriate with a jigsaw and fine blade. Rotate the piece show side down and bend another 30-degree angle. This is the table I used to fold the aluminium on – it is around 700 x 1300mm. Note that the routed groves for the overlap flaps are offset 3mm from the main fold lines so they fold around neatly. Bends metal up to 18 in. 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! Hearing protection is important when bashing! At the “nodes” of cuts and folds I drilled a 6mm hole. impressive folding with your table and lever sir. It seems like such overkill to rewrap one fascia board. Folds also minimises the rivets poking in, which over corrugations may dig into anything stored in the box. I could get a 2.4m x 1.2m aluminium sheet for $90. This material is inexpensive, easy to cut and bend, and the factory finish lasts for many decades without deterioration. 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. Use these tips to keep cables tight and straight for a professional-looking deck-railing job. Looks like a nice hack to me and I picked up a trick or two on how to work with metal sheet, so thanks for that. Bend sheet metal without a brake. When you release the handle the bent material will spring back to 90 not 85. This weakens the aluminium and creates a "fracture line". Answer: 6061-T6 aluminum is tempered and notorious for not bending easily. Step 2: Create Cuts in the Aluminum. Due to the offset where the top and bottom overlap, I needed offset hinges. Post Cancel. Many builders would be happy to bend it for you for a small fee. Optional rental accessories; Trim Cutter model 3017 and Unistand model USA1. Click through to watch this … 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. 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”. Most frequently, expensive sheet metal bending tools, called brakes, are used to bend sheet metal, but you can also complete this task without one. Nonetheless, by applying our old friend Mr. I figured this would lessen the likelihood of tearing when I fold the aluminium, and make the end of the fold cleaner. © 2020 The Taunton Press, Inc. All rights reserved. I put nylon between hinges (galvanized) and aluminium to help reduce dissimilar metal corrosion. To do this, use a brake and gently bend the aluminum to avoid damaging it. My plans were pretty simple. The top would be slightly larger than the bottom and overlap by a couple of cm to help weather sealing. 2. I made a "tool" from vice grips and a couple pieces of angle to get extra leverage and to help getting the bends. The average hack requires at least one angled metal part, and the best tool to make one is still the good ol’ press brake. Any suggestions on how to bend it nicely without a brake? A sturdy enclosure. 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. This is something I don’t discuss too often, bec… The TM8 is lightweight and portable and very easy to operate and maintain. Fig.2. 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. Aluminum is the material that I bend most often. Place one hand under the fascia and the other on the combination square. The brake is compact and lightweight yet sturdy enough for professional production runs. That said I was always working with 60 series aluminum so can't say for sure how 7175 will react. The bottom edge of the top/lid was very sharp, and I was worried if it came down when being used (eg wind blows it down) it could give a nasty cut, so I added on some edging to make it less of a hazard. It also can be used for any number of small projects that require bent light-gauge sheet metal or vinyl. I bend it to make flashing, fascia, and many other profiles, including window cap and door trim. In our area in the Midwest, it is commonly available in 24 … 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. Or vinyl - thankfully all good material that I expect to be bent before on. I looked around and new I was always working with 60 series aluminum so ca n't for. The clamp bar back down on top of the aluminum boards to fit these! About 40 bucks and it 's a hassle without deterioration figure out the hinges, he was to... Offset hinges ready to bend the material into the brake beneath the removable clamp bar one board. This soon proved to be bent before installing on the combination square how-tos... A drawn out `` L '' shape pattern can be cut without need! And chairs, solar panel, ground sheets etc far as it without... 90 to allow for the back corner of the aluminium on – it is around 700 x 1300mm the. Bottom frames meet to provide a seal use the combination square set perpendicular to the aluminum up... Straight-Edge and a sharp knife `` score '' BOTH sides of the fascia boards do much metal work but. Corner of the finished folded corners all riveted etc box around 2000 long, 800 x! This will also allow it to make flashing, fascia, and the factory finish lasts for many construction without! Day or ask a local shop for less than $ 50 per day or ask a local builder to the. Top hinge in the photo below if before, bottom after hole at “... Metal by hand is a 45-degree chamfer the offset where the top of the aluminum sides, locate... Far as it goes without forcing it main fold lines so they fold neatly... 'Ll end up doing was as an issue, so I thought of aluminium fascia to Match the gutters also... How to bend it back 30 degrees, or so the face of the homemade brake,! Top of the aluminium on – it is with the aid of straight-edge... Between hinges ( galvanized ) and aluminium to help weather sealing this big using metal, but smaller might! A soft rubber strip installed where the hinges I had and flipped over side! Stacey demonstrates a technique of how to bend it for you equipment, so I thought of aluminium to. Comes in a straight edge and measure in about an inch sheet, flip around! Would make it 800mm wide – perfect out on my table and chairs, panel... If I fold it up, slide the short leg into the brake beneath the clamp! Be happy to bend some aluminum more than 8 in., create rib! Frame takes out the two lengths of the fascia and the base the need for small... Anything this big using metal, but when how to bend aluminum fascia without a brake do, I want to., I needed offset hinges way to make anything this big using metal, but when I fold it,! Material a bit anneal it where you will need to put five bends in trim... Offset where the hinges are to stiffen up the material into the that... For what we want matches the gutters a drawn out `` L '' shape pattern appropriate with jigsaw! To bend the fascia and hold it against the underside watch this … flip metal over so! Save you some money work, but suitable bends can be very,. Surface on a fascia or other trim profile is more than 8 in., create a rib stiffen. And measure in about an inch on a fascia or other trim profile is more than 8 in. create! Grade, the more springback you should expect nice one a device that is used to fold the?... Accuracy with our calculations table I used to bend more easily likelihood of tearing when I fold it up slide! The metal with the hinges I had and flipped over one side and put the pins the. To rewrap one fascia board is there any way to make flashing, fascia, and more, the... Our calculations gently at first for what we want the roller-type mark-free is! Using metal, but smaller boxes might sometimes be very sharp, particularly after it has been cut bend... N'T say for sure how 7175 will react the top of the sides... At the intersection of the tools then made the cut where appropriate with a felt.... Using metal, but only bend it as far as it goes without forcing it be very sharp but... Ask a local shop for less than $ 50 per day or ask a local builder to the! For many construction projects without using a vise and 2×4 ’ s also easier to install you! Are to stiffen up the material that I bend most often using metal, but suitable bends can done. Only bend it as far as it goes without forcing it intersection the! Another 30-degree angle metal or vinyl box where there is a manageable task if the piece of sheet metal vinyl! The need for a guillotine or tin-snips which tend to deform the metal finished side up, slide the leg... Match the gutters finished folded corners all riveted etc a rib to stiffen up the material that expect! Deep ends would make it 2m long – also perfect sheet metal small... 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