How to bend sheet metal and get a proper bend radius

[MitchellB]

When I made and installed my own aluminum facias, eves and trim around our house before I installed our gutters, I made an 8 foot brake from three 2x4s, door hinges and big C-clamps fastened to a table top. You could use a router to chamfer the radius you needed to the board you are bending it around. I bent thin aluminum in 8 foot lengths, but by using heavier wood construction you should be able to bend thicker aluminum material.

 

[BHD]

do not know if it works or not found it the other night looking for some thing else, then read this

Tools

another that caught my eye,

http://toolplans.com/?p=55

 

[ETpilot]

Since you are a member of EAA buy the home builder books, about 4 books, by Tony Bingelis. He has a lot of useful information and techniques for the home builder. Also go to the Sonex Aircraft website and look for builder's network. You will find other builders who post step by step process of their build. You will find it most helpful

Check out Van's Airforce. While this site is specific for Van model aircraft, there is a lot of good info there for the home builder; aircraft, engines, avionics, painting, tools, etc.

I, once, almost ordered the tail kit for a Van's RV-10. But, I could not give up my Cessna T210. So I am still flying the old bird here and there. I guess it will be the last airplane for me.

 

[philbuilt]

Here are a couple of tips for working with aluminum sheets. For cutting sheet use your
Router with a 1/4" shank 1/2" dia carbide cutter with a center bearing. Buy an 8' piece of
2" flat bar and DA tape it to the piece on line. Wax the line and cut. Paraffin wax works and is easy to clean off.
Or you can use a end bearing just tape flat bar to the bottom of the sheet.
Also check out Www.lowbucktools.com . I have bought some stuff and it works. I use there
Louvre press. You may want to build the stand an adapt some of the other tools as well.

 

[lstinthot]

Thanks for the links. I may have to build a larger brake like one of those.

do not know if it works or not found it the other night looking for some thing else, then read this

Tools

another that caught my eye,

Tool Plans» Blog Archive » Build A Sheet Metal Brake