Nonetheless, by applying our old friend Mr. Thanks. Use these tips to keep cables tight and straight for a professional-looking deck-railing job. Bend up 90 degrees. There are many ways to get the job done without having all of the tools. The TM10 is lightweight and portable and very easy to operate and maintain. 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. When you release the handle the bent material will spring back to 90 not 85. "I have learned so much thanks to the searchable articles on the FHB website. The brake is compact and lightweight yet sturdy enough for professional production runs. I need to put five bends in a 10 ‘ length of aluminium fascia to match existing pieces. Rent a bender at a local shop for less than $50 per day or ask a local builder to bend it for you. 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). Start your subscription today and save up to 52%. Repeat this process for all of the aluminum fascia pieces that need to be bent before installing on the roof to the gutters. After assembling a few of these pieces with some hinges, he was ready to bend some aluminum. I guess that's what I'll end up doing. The average hack requires at least one angled metal part, and the best tool to make one is still the good ol’ press brake. Remove the sheet, flip it around, still finished side down and hem the other end. Use a ladder to reach the area where you will hang the fascia boards. 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. 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. Bending sheet metal by hand is a manageable task if the piece of sheet metal is small and thin enough to handle. 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. Insert your aluminum sheet into the brake beneath the removable clamp bar. A sturdy enclosure. Top hinge in the photo below if before, bottom after. 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. It seems like such overkill to rewrap one fascia board. Use the combination square set perpendicular to the aluminum fascia and hold it against the underside. If you use a metal break, you usually bend all the metal from aluminum trim coil. At the “nodes” of cuts and folds I drilled a 6mm hole. Step 2: Create Cuts in the Aluminum. Finished product all mounted and ready to go. It’s also easier to install than you might think. Step 4 – Hang the Fascia Boards. Stacey demonstrates a technique of how to bend a sheet of metal using a vise and 2×4’s. 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. You will have a drawn out "L" shape pattern. That sort of worked, but it just looked hideous. 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 dont think I would have tried to make anything this big using metal, but smaller boxes might sometimes be very handy. To do this, use a brake and gently bend the aluminum to avoid damaging it. 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 knocked the pins out the hinges I had and flipped over one side and put the pins back in. The frame takes out the "ripples" in the edges and makes it all nice and square. 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. 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. The greater the bend radius, the less of an issue it will be. Take a section of plywood, and clamp it down stationary. 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. 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”. Move slowly along the fold, doing 10 – 20 degree bends at a time. This weakens the aluminium and creates a "fracture line". Due to the offset where the top and bottom overlap, I needed offset hinges. This is something I don’t discuss too often, bec… From a bending perspective, it’s always best to bend these parts in an annealed state and then temper them to the correct condition. Line the aluminum piece up with the combination square in a straight edge and measure in about an inch. Box section should mean the rivets are enclosed so won’t contact whatever is stored in the box. Fig.2. Aluminum also requires a calculation of the bend radius based on the thickness of the aluminum. 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. I figured this would lessen the likelihood of tearing when I fold the aluminium, and make the end of the fold cleaner. And 200 mm deep ends would make it 2m long – also perfect. Get complete site access to expert advice, how-to videos, Code Check, and more, plus the print magazine. This material is inexpensive, easy to cut and bend, and the factory finish lasts for many decades without deterioration. 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. 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. Flip metal over, so that the finished side is down, bend 90 degrees. If it is showing cracking or just plain fractures, anneal it where you will be bending it. The TM8 is lightweight and portable and very easy to operate and maintain. Comment. Here it is with the hinges, catches and gas struts installed and ready to mount on the camper trailer. Then, place the clamp bar back down on top of the aluminum crosswise. 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 structure of the roller-type mark-free die is shown in Fig. Sheet aluminium can be cut without the need for a guillotine or tin-snips which tend to deform the metal. Figure out the two lengths of the aluminum sides, to locate where the bend will be. 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 then made the cut where appropriate with a jigsaw and fine blade. I put nylon between hinges (galvanized) and aluminium to help reduce dissimilar metal corrosion. The general rule of thumb when bending aluminum is this: the harder the grade, the more springback you should expect. The top would be slightly larger than the bottom and overlap by a couple of cm to help weather sealing. 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. Step 4: Bend the Fascia to Match the Gutters. Place one hand under the fascia and the other on the combination square. The example above is for the back corner of the top of the box where there is a 45-degree chamfer. The bend won't be quite as sharp, but suitable bends can be made for many construction projects without using a brake. Grab the top of the metal with the pliers as the section you heated cools off and pull towards you gently at first. Senior Member. This is the table I used to fold the aluminium on – it is around 700 x 1300mm. 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. Place the "fracture-line" over the edge of a table and bend the overhang SLIGHTLY downwards. This will give you a nice bend. With the show side up, make about a 30-degree bend. I also used some offcuts to make doubler plates where the hinges are to stiffen up the material a bit. Renting a brake is about 40 bucks and it's a hassle. 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. Bends metal up to 18 in. 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. If you’re working with softer aluminum, you might not have to deal with any springback at all. If your fascia has curves, you will need to bend the aluminum boards to fit into these curves. I can confidently say that I expect to be a life-long subscriber." Gently push up to bend the material into the angle that matches the gutters. 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. 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. A brake tool is a device that is used to bend aluminum and other metals. The two M10 bolts in the top are to clamp the sheet between the backstop and the base. 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. So I thought about building my own. Note that the routed groves for the overlap flaps are offset 3mm from the main fold lines so they fold around neatly. Step 3: Bend the Aluminum. I don't do much metal work, but when I do, I want it to look crisp. Good luck! Any suggestions on how to bend it nicely without a brake? Existing box was about 400 deep. Post Cancel. Photo of the finished folded corners all riveted etc. Move slowly along the fold, doing 10 – 20 degree bends at a time. 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