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