Folds also minimises the rivets poking in, which over corrugations may dig into anything stored in the box. If the exposed surface on a fascia or other trim profile is more than 8 in., create a rib to stiffen it. Flip the metal finished side up, slide the short leg into the brake, and bend another 90. So I thought about building my own. I also used some offcuts to make doubler plates where the hinges are to stiffen up the material a bit. I knocked the pins out the hinges I had and flipped over one side and put the pins back in. One guy suggested a 9" seamer. I used an acid based silastic as a glue/sealer. Stacey demonstrates a technique of how to bend a sheet of metal using a vise and 2×4’s. Here it is with the hinges, catches and gas struts installed and ready to mount on the camper trailer. 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. Aluminum comes in a variety of widths, colors, thicknesses, and finishes. 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. Warning – the edges of the aluminium can be very sharp, particularly after it has been cut. I don't do much metal work, but when I do, I want it to look crisp. Repeat this process for all of the aluminum fascia pieces that need to be bent before installing on the roof to the gutters. The two M10 bolts in the top are to clamp the sheet between the backstop and the base. 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. 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 has degraded over time (cracks, hinge broken) and needed replacing. Any suggestions on how to bend it nicely without a brake? The structure of the roller-type mark-free die is shown in Fig. I need to put five bends in a 10 ‘ length of aluminium fascia to match existing pieces. That sort of worked, but it just looked hideous. wide; Handles material as thick as 16 gauge; Makes bends to 90º; Easily clamps or mounts to workbench Weight was as an issue, so I thought of aluminium. 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”. Did you make this project? With the show side up, make about a 30-degree bend. I dont think I would have tried to make anything this big using metal, but smaller boxes might sometimes be very handy. "I have learned so much thanks to the searchable articles on the FHB website. Rotate the piece show side down and bend another 30-degree angle. 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. Fig.2. The top would be slightly larger than the bottom and overlap by a couple of cm to help weather sealing. 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 guess that's what I'll end up doing. Step 3: Bend the Aluminum. Rent a bender at a local shop for less than $50 per day or ask a local builder to bend it for you. The general rule of thumb when bending aluminum is this: the harder the grade, the more springback you should expect. 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. Step 1: Acquire a Brake Tool. Step 4: Bend the Fascia to Match the Gutters. Bend up 90 degrees. I figured folding means you don’t have to seal the edges, and as the fold is one piece and should be strong enough. This returns the J-channel. Hem the seam. 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 motor mount. I have never tried this method, but if you don’t have a metal brake, this may work fine. Also note the hole at the intersection of the folds so you don't get tearing. 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. Thanks. 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!! 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. Most frequently, expensive sheet metal bending tools, called brakes, are used to bend sheet metal, but you can also complete this task without one. 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. Use the combination square set perpendicular to the aluminum fascia and hold it against the underside. The frame takes out the "ripples" in the edges and makes it all nice and square. There are many ways to get the job done without having all of the tools. 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. Get complete site access to expert advice, how-to videos, Code Check, and more, plus the print magazine. 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. The bend won't be quite as sharp, but suitable bends can be made for many construction projects without using a brake. A brake tool is a device that is used to bend aluminum and other metals. The greater the bend radius, the less of an issue it will be. You will have a drawn out "L" shape pattern. Become a member and get instant access to thousands of videos, how-tos, tool reviews, and design features. 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. With the aid of a straight-edge and a sharp knife "score" BOTH sides of the aluminium sheet. 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). If it is showing cracking or just plain fractures, anneal it where you will be bending it. It won’t make the centrefold of metalwork monthly, but it worked out way beyond my expectations will be perfect for what we want. Oldgrandad. 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. 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. Mathematics, we can achieve extreme accuracy with our calculations. Check out these seven tips for successfully bottom bending aluminum with your press brake: 1. 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. Answer: 6061-T6 aluminum is tempered and notorious for not bending easily. So two sheets should make a box around 2000 long, 800 wide and 400 deep. Box section should mean the rivets are enclosed so won’t contact whatever is stored in the box. Is there any way to make long bends in aluminum trim coil without a brake? Figure out the two lengths of the aluminum sides, to locate where the bend will be. The brake is compact and lightweight yet sturdy enough for professional production runs. 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. Then, place the clamp bar back down on top of the aluminum crosswise. This soon proved to be indispensable and stores all our bulky gear – folding table and chairs, solar panel, ground sheets etc. If you need to, reheat the metal and redo the bend. The metal should bend, but only bend it as far as it goes without forcing it. 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. It’s also easier to install than you might think. Use a ladder to reach the area where you will hang the fascia boards. 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. Renting a brake is about 40 bucks and it's a hassle. Senior Member. 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. Save up to bend it for you for a second hand one it for you for second... Shown in Fig lessen the likelihood of tearing when I do n't get tearing,... 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