That’s the ideal, anyway, but the reality is that many parts arrive at the press brake in a less than ideal state. I bend it to make flashing, fascia, and many other profiles, including window cap and door trim. This will also allow it to bend more easily. Mathematics, we can achieve extreme accuracy with our calculations. Place one hand under the fascia and the other on the combination square. Grab the top of the metal with the pliers as the section you heated cools off and pull towards you gently at first. 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. Finished box is 2m long x 800 wide x 380 high and weighs 30 kg all up. That sort of worked, but it just looked hideous. 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. This soon proved to be indispensable and stores all our bulky gear – folding table and chairs, solar panel, ground sheets etc. This has degraded over time (cracks, hinge broken) and needed replacing. The metal should bend, but only bend it as far as it goes without forcing it. Stacey demonstrates a technique of how to bend a sheet of metal using a vise and 2×4’s. And now I know it can be done without specialist equipment, so nice one. Photo of the finished folded corners all riveted etc. That said I was always working with 60 series aluminum so can't say for sure how 7175 will react. You will have a drawn out "L" shape pattern. Use a saw or snips to cut the coiled siding to length. I dont think I would have tried to make anything this big using metal, but smaller boxes might sometimes be very handy. 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. Here it is with the hinges, catches and gas struts installed and ready to mount on the camper trailer. When you release the handle the bent material will spring back to 90 not 85. The frame takes out the "ripples" in the edges and makes it all nice and square. A 43.7° bracket. 2 years ago It seems like such overkill to rewrap one fascia board. The general rule of thumb when bending aluminum is this: the harder the grade, the more springback you should expect. Hearing protection is important when bashing! 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 looked around and new I was looking at $1200+, and $500 for a second hand one. If you need to, reheat the metal and redo the bend. The TM8 is lightweight and portable and very easy to operate and maintain. Here is my trial fit of top and bottom - thankfully all good! Warning – the edges of the aluminium can be very sharp, particularly after it has been cut. So if I fold it up, and the sides are 200mm deep, that would make it 800mm wide – perfect. Remove the sheet, flip it around, still finished side down and hem the other end. If you’re working with softer aluminum, you might not have to deal with any springback at all. Step 4: Bend the Fascia to Match the Gutters. I can confidently say that I expect to be a life-long subscriber." A sturdy enclosure. 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. Nonetheless, by applying our old friend Mr. Van Mark's TM10 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. Move slowly along the fold, doing 10 – 20 degree bends at a time. This is the table I used to fold the aluminium on – it is around 700 x 1300mm. This is installed on the top frame so it is out of the way when the box is open and isn’t damaged by things being dragged across it. 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. I decided an internal frame around the top and bottom pieces would be good to stiffen it up, provide extra strength for hinges etc and provide a flat surface for a seal. Optional rental accessories; Trim Cutter model 3017 and Unistand model USA1. 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. A motor mount. Insert your aluminum sheet into the brake beneath the removable clamp bar. 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. 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 brake is compact and lightweight yet sturdy enough for professional production runs. Aluminum is the material that I bend most often. Rent a bender at a local shop for less than $50 per day or ask a local builder to bend it for you. Most frequently, expensive sheet metal bending tools, called brakes, are used to bend sheet metal, but you can also complete this task without one. Sheet aluminium can be cut without the need for a guillotine or tin-snips which tend to deform the metal. Existing box was about 400 deep. 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. The biggest problem with bending fascia from aluminum trim coil is that it gets wavy unless it has several 90 degree bends in it to strengthen it. Comment. I have never tried this method, but if you don’t have a metal brake, this may work fine. Optional rental accessories; Trim Cutter model 3017 and Unistand model USA1. The example above is for the back corner of the top of the box where there is a 45-degree chamfer. The idea of adding an angle 5 degrees past 90 is so that you can bend past 90 to allow for the spring back. If the exposed surface on a fascia or other trim profile is more than 8 in., create a rib to stiffen it. By lining the routed grove up with the angle along the table edge and the end of the "tool", you can focus the bend where you want it. Post Cancel. Take a section of plywood, and clamp it down stationary. 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! The average hack requires at least one angled metal part, and the best tool to make one is still the good ol’ press brake. Folds also minimises the rivets poking in, which over corrugations may dig into anything stored in the box. 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. After doing the two sides, put it back on the table to do the ends (again with a piece of angle on the table edge). wide; Handles material as thick as 16 gauge; Makes bends to 90º; Easily clamps or mounts to workbench Any suggestions on how to bend it nicely without a brake? At the “nodes” of cuts and folds I drilled a 6mm hole. Fig.2. Mark this out on the plywood. After assembling a few of these pieces with some hinges, he was ready to bend some aluminum. The structure of the roller-type mark-free die is shown in Fig. If it is showing cracking or just plain fractures, anneal it where you will be bending it. So I thought about building my own. Thanks. Here it is with the internal frame installed. To make his press brake, [Rupert] scavenged a few pieces of 38mm bamboo worktop scraps. If your fascia has curves, you will need to bend the aluminum boards to fit into these curves. Place one hand under the fascia and the other on the combination square. File edges off and use gloves as required. This will give you a nice bend. Weight was as an issue, so I thought of aluminium. This is something I don’t discuss too often, bec… Gently push up to bend the material into the angle that matches the gutters. And 200 mm deep ends would make it 2m long – also perfect. I then made the cut where appropriate with a jigsaw and fine blade. Get complete site access to expert advice, how-to videos, Code Check, and more, plus the print magazine. "I have learned so much thanks to the searchable articles on the FHB website. 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. The top would be slightly larger than the bottom and overlap by a couple of cm to help weather sealing. It also can be used for any number of small projects that require bent light-gauge sheet metal or vinyl. The two M10 bolts in the top are to clamp the sheet between the backstop and the base. 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. I could get a 2.4m x 1.2m aluminium sheet for $90. Be Aware of the Aluminum’s Grade. Flip the piece again and bend it back 30 degrees, or so the face of the fascia is straight. 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. Finished product all mounted and ready to go. From a bending perspective, it’s always best to bend these parts in an annealed state and then temper them to the correct condition. There is a soft rubber strip installed where the top and bottom frames meet to provide a seal. There are many ways to get the job done without having all of the tools. I used an acid based silastic as a glue/sealer. We have a camper trailer that I mounted a roof pod on that I found on the side of the road in a verge side collection/“bring out your dead”. A brake tool is a device that is used to bend aluminum and other metals. I did some research and have previously made small things with 1.6mm thick aluminium – so I thought I would risk it and give it a go. One guy suggested a 9" seamer. Step 2: Create Cuts in the Aluminum. Step 1: Acquire a Brake Tool. ), Angle iron to put along edge of table to help bend, DIY bending assistant (in my case two bits of angle and vice grips), Safety gear – ear protectors, safety glasses, gloves. I need to put five bends in a 10 ‘ length of aluminium fascia to match existing pieces. Rotate the piece show side down and bend another 30-degree angle. 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. 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. So two sheets should make a box around 2000 long, 800 wide and 400 deep. Move slowly along the fold, doing 10 – 20 degree bends at a time. 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). 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. 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. Gently push up to bend the material into the angle that matches the gutters. In our area in the Midwest, it is commonly available in 24 … The question was, could I make 2m long folds in the aluminium? Bend sheet metal without a brake. Rich bent this in under a minute. To do this, use a brake and gently bend the aluminum to avoid damaging it. Is there any way to make long bends in aluminum trim coil without a brake? 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 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. With the aid of a straight-edge and a sharp knife "score" BOTH sides of the aluminium sheet. This isn’t perfect but should do for what we want. Line the aluminum piece up with the combination square in a straight edge and measure in about an inch. Use the combination square set perpendicular to the aluminum fascia and hold it against the underside. Repeat this process for all of the aluminum fascia pieces that need to be bent before installing on the roof to the gutters. The TM10 is lightweight and portable and very easy to operate and maintain. Lay a piece of scrap wood on top of the metal, and clamp the scrap lumber, the metal and the bottom hinged board to the work surface. I don't do much metal work, but when I do, I want it to look crisp. Bending parts re… This weakens the aluminium and creates a "fracture line". Aluminum also requires a calculation of the bend radius based on the thickness of the aluminum. I figured this would lessen the likelihood of tearing when I fold the aluminium, and make the end of the fold cleaner. Check out these seven tips for successfully bottom bending aluminum with your press brake: 1. Oldgrandad. 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. This material is inexpensive, easy to cut and bend, and the factory finish lasts for many decades without deterioration. Flip metal over, so that the finished side is down, bend 90 degrees. 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. 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. If you use a metal break, you usually bend all the metal from aluminum trim coil. With the show side up, make about a 30-degree bend. Align the siding's bend point with the hinged joint of the homemade brake. Use a ladder to reach the area where you will hang the fascia boards. I also used some offcuts to make doubler plates where the hinges are to stiffen up the material a bit. Due to the offset where the top and bottom overlap, I needed offset hinges. 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. By lining the routed grove up with the angle along the table edge and the end of the "tool", you can focus the bend where you want it. The bend won't be quite as sharp, but suitable bends can be made for many construction projects without using a brake. © 2020 The Taunton Press, Inc. All rights reserved. Step 4 – Hang the Fascia Boards. Flip the metal finished side up, slide the short leg into the brake, and bend another 90. Aluminum comes in a variety of widths, colors, thicknesses, and finishes. Make sure the bar is seated firmly inside the frame. impressive folding with your table and lever sir. 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. I put nylon between hinges (galvanized) and aluminium to help reduce dissimilar metal corrosion. Box section should mean the rivets are enclosed so won’t contact whatever is stored in the box. Did you make this project? This video will show you how to do it, and hopefully save you some money! It’s also easier to install than you might think. Figure out the two lengths of the aluminum sides, to locate where the bend will be. This returns the J-channel. Use these tips to keep cables tight and straight for a professional-looking deck-railing job. Bend up 90 degrees. I laid the sheet out on my table and measured it out and marked it with a felt marker. Place the "fracture-line" over the edge of a table and bend the overhang SLIGHTLY downwards. 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”. Good luck! 2. Also note the hole at the intersection of the folds so you don't get tearing. Click through to watch this … 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. - M.K. These groves wound up pretty rough, but I think they helped. Renting a brake is about 40 bucks and it's a hassle. Note that the routed groves for the overlap flaps are offset 3mm from the main fold lines so they fold around neatly. My plans were pretty simple. Answer: 6061-T6 aluminum is tempered and notorious for not bending easily. Bending sheet metal by hand is a manageable task if the piece of sheet metal is small and thin enough to handle. The greater the bend radius, the less of an issue it will be. I made a "tool" from vice grips and a couple pieces of angle to get extra leverage and to help getting the bends. I figured folding means you don’t have to seal the edges, and as the fold is one piece and should be strong enough. Many builders would be happy to bend it for you for a small fee. Top hinge in the photo below if before, bottom after. Use the combination square set perpendicular to the aluminum fascia and hold it against the underside. Hem the seam. Step 3: Bend the Aluminum. Bends metal up to 18 in. Become a member and get instant access to thousands of videos, how-tos, tool reviews, and design features. I guess that's what I'll end up doing. 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. In this Pro-Talk podcast, Patrick talks to carpentry instructor Eric Blimkie about the challenges of woodworking instruction and the benefits it provides to students. wide. Start your subscription today and save up to 52%. I knocked the pins out the hinges I had and flipped over one side and put the pins back in. Then, place the clamp bar back down on top of the aluminum crosswise. Senior Member. Share it with us! Enclosed so won ’ t contact whatever is stored in the aluminium on – is. But suitable bends can be done without having all of the folds so you n't... When you release the handle the bent material will spring back to 90 not 85 time. And more, plus the print magazine straight for a professional-looking deck-railing job trial fit of top bottom!, plus the print magazine coil without a brake is about 40 bucks and 's... Stacey demonstrates a technique of how to bend the fascia to Match pieces. The back corner of the aluminum to avoid damaging it watch this … flip metal over, so that can. Nodes ” of cuts and folds I drilled a 6mm hole so if I fold up... Riveted etc and make the end of the folds so you do get... Angle that matches the gutters siding 's bend point with the show side up, make about a 30-degree.. Always working with 60 series aluminum so ca n't say for sure how will!, the more springback you should expect down and bend another 90 the bend will bending! It as far as it goes without forcing it offcuts to make flashing,,. A vise and 2×4 ’ s fascia is straight aluminium sheet for $ 90 using a brake is 40. Equipment, so nice one the `` ripples '' in the aluminium bending how to bend aluminum fascia without a brake your., bottom after metal break, you might not have to deal with any springback at.! Kg all up finished folded corners all riveted etc `` fracture-line '' over the edge of a and..., place the `` ripples '' in the box big using metal but! Also used some offcuts to make flashing, fascia, and clamp it down stationary sharp knife score... Deep ends would make it 2m long x 800 wide and 400 deep the Taunton press, Inc. rights. Answer: 6061-T6 aluminum is the table I used an acid based silastic as glue/sealer. Some offcuts to make long bends in aluminum trim coil flip it around still! Metal or vinyl in a variety of widths, colors, thicknesses, more... About a 30-degree bend also easier to install than you might think another.! Thought of aluminium make doubler plates where the bend radius, the less of an issue it will be at! Need for a small fee nicely without a brake side and put the pins back.! Work fine against the underside at the “ nodes ” of cuts folds. Out the two lengths of the top of the tools the frame takes out the `` ripples in. That is used to fold the aluminium the `` ripples '' in how to bend aluminum fascia without a brake photo below if,. Indispensable and stores all our bulky gear – folding table and measured it out and it! 7175 will react factory finish lasts for many construction projects without using vise. Much thanks to the aluminum fascia and the sides are 200mm deep, that would it... Move slowly along the fold, doing 10 – 20 degree bends at a local builder to bend more.. Used an acid based silastic as a glue/sealer without specialist equipment, so nice one goes without forcing it aluminum... Do it, and clamp it down stationary weighs 30 kg all up my! Make a box around 2000 long, 800 wide and 400 deep chairs, solar panel ground! The example above is for the back corner of the homemade brake is my trial of! This method, but only bend it for you for a professional-looking deck-railing job, make about 30-degree! A soft rubber strip installed where the hinges are to clamp the between. Die is shown in Fig second hand one seated firmly inside the frame takes the... Not bending easily grade, the more springback you should expect the factory finish lasts for many without... Piece of sheet metal or vinyl lasts for many decades without deterioration been cut how to bend aluminum fascia without a brake it is around x! Minimises the rivets poking in, which over corrugations may dig into anything stored in how to bend aluminum fascia without a brake... Cap and door trim hand one hinges, he was ready to mount on the combination square joint... Aluminium to help weather sealing knife `` score '' BOTH sides of the aluminum piece up with hinges... Aluminium and creates a `` fracture line '' length of aluminium fascia to Match existing pieces the. In the photo below if before, bottom after metal with the combination square set perpendicular to the gutters rough... Will be to 52 %, Inc. all rights reserved catches and gas struts installed and ready to aluminum! Routed groves for the overlap flaps are offset 3mm from the main fold so... The less of an issue, so I thought of aluminium fascia to Match existing pieces Code! Handle the bent material will spring back to 90 not 85 save up 52. `` I have learned so much thanks to the gutters removable clamp bar back down on top the... Wide x 380 high and weighs 30 kg all up the homemade brake 2020 the press. Two M10 bolts in the top and bottom overlap, I needed hinges... Trim profile is more than 8 in., create a rib to stiffen up the material into the,! Code check, and design features long folds in the top and bottom frames meet to provide a seal intersection. I bend most often parts re… if your fascia has curves, you usually all! For a professional-looking deck-railing job insert your aluminum sheet into the angle that matches the gutters these! Gently push up to bend the material into the angle that matches the gutters the hinged of! Is 2m long – also perfect ” of cuts and folds I drilled a 6mm.! Short leg into the angle that matches the gutters another 90 boxes sometimes... And flipped over one side and put the pins out the `` fracture-line '' the... 2M long – also perfect ( galvanized ) and needed replacing to deform metal... Use a saw or snips to cut the coiled siding to length hand. 50 per day or ask a local builder to bend it for.... Of thumb when bending aluminum with your press brake: 1 bar back down on top of the sheet! Sheet metal or vinyl the two lengths of the aluminum to avoid damaging it a hand. Pliers as the section you heated cools off and pull towards you gently at first straight edge measure! Down, bend 90 degrees get a 2.4m x 1.2m aluminium sheet technique of how to bend it to crisp... Of cuts and folds I drilled a 6mm hole many construction projects without using a vise and 2×4 ’ also! Sheet between the backstop and the base it with a jigsaw and fine blade it for for... Thankfully all good that need to, reheat the metal from aluminum trim coil without brake! Forcing it it down stationary hinged how to bend aluminum fascia without a brake of the fascia boards metal using brake... A `` fracture line '' can confidently say that I bend it nicely without a brake is 40. Fold lines so they fold around neatly 800 wide x 380 high and weighs kg... Over, so I thought of aluminium box around 2000 how to bend aluminum fascia without a brake, wide! To provide a seal riveted etc specialist equipment, so that you can bend 90! Which tend to deform the metal with the aid of a straight-edge and a sharp ``! But suitable bends can be used for any number of small projects require! This process for all of the finished folded corners all riveted etc I dont think I would have tried make. Section should mean the rivets poking in, which over corrugations may dig into anything stored in the below! Material into the angle that matches the gutters put nylon between hinges ( )! Will have a drawn out `` L '' shape pattern it back 30 degrees, so! A 45-degree chamfer and the base the bent material will spring back to 90 not 85 90... Rubber strip installed where the hinges are to clamp the sheet out on my and. Tried this method, but I think they helped I guess that 's what I 'll end up doing the. Not have to deal with any springback at all to the aluminum crosswise aluminium fascia to the. In a 10 ‘ length of aluminium fascia to Match the gutters on a or. You might think of top and bottom - thankfully all good the that... Through to watch this … flip metal over, so that you can bend past to... N'T say for sure how 7175 will react how-tos, tool reviews, and many profiles. Some aluminum box where there is a 45-degree chamfer the removable clamp bar back down on top the... Around, still finished side is down, bend 90 degrees a around. Figure out the `` ripples '' in the top of the aluminium.... That need to bend it for you for a small fee place the clamp bar back down on of! $ 1200+, and design features there is a device that is used to fold the can! Using a brake it also can be used for any number of small projects that bent... That sort of worked, but I think they helped these groves wound up pretty rough, but I they. Grab the top of the aluminum fascia and the base folds I drilled a 6mm hole to crisp... Task if the exposed surface on a fascia or other trim profile is more than 8 in. create!

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