3/8 Press Brake - Homemade press brake … There's been more than a few times I've needed to bend metal and I've resorted to clamping 2x4s together and using a hammer. Place and adjust the bender to bed with the metal strip between them, and keep it in place using clamps. 77. You will need a steel rod that's at least the same diameter as the carriage bolts. The hole was tapped for a 3/8" bolt. With the folding angle still clamped in place, I marked the hinge holes on the bending angle, unclamped it, used the metal punch, and drilled 1/4" holes, recessing the heads with a 1/2" bit. Steps 1. You can see some modifications about this brake in my YouTube video. Select materials that will be strong enough for your needs. For Release System we need 2pcs Spring coils ø2mm 4~5 turns and 2pcs washers ø30x10.5mm. Wonderful idea and awesome workmanship. I cut out 1/2" off each corner of the bending angle for the hinge cylinder with the hack saw and then smoothed the cuts with the grinder and file. A cornice brake has a solid clamping bar, the full width of the machine; thus, it can only make straight bends, the entire width of the workpiece. A third angle has handles and is hinged to the 2x4. 3 years ago. A kitchen product like cream of tartar may be relatively expensive but if … The use of a new unused 180mm grinding disk is required for best performance. Go very slowly. • Wear old clothes for painting. The hold down clamps down the metal to be bent. You need to cook them, but that's in my tutorial. For brake's bed I have use my hydraulic portable table. I had these on hand, and (2) per screw put the hinge at the right height.• (2) 5/16" x 2.5" Carriage Bolts - for the hold down. At starting do not use any pressure on the grinder, let it work with its own weight, and then push it very gently and with the same pressure from one end to other. The most important thing on a sheet metal brake is: Twist a steel wire ø1.2mm around the pivot and place it at the gap on edge of bender. It would seem that this could be built out of 2x4 faced with a steel surface(like heavy gauge sheet metal), and get the job done for a lot less. I'm going to do this two tone though. this guide is SOO much better than the one I was making. I can not bend as heavey as yours maybe but every shop could use one. According to dimensions of your grinder the height of the slider (tube+flat bar 3mm) must be, so as the grinding disk to beabsolutely parallel to surface of base. Make pauses when you are on one end of angle to cool down, or use water to helping it stay cool.After some passes and when the grinding sides, start to have different width or have already grind about 1.5mm of the height, remove the (3mm) flat bar and continue to slide the grinder direct up to the tube. The main reason I needed a press brake was to bend some truly obnoxious steel plate I bought. Remove the brake and drill the holes starting with a ø4mm drill bit. I discovered it would be nice if the hold down would pop up when not in use to allow metal to slide in easily. I've bent 1/16" aluminum and metal easily. The edges contacting the center plate have a slight radius. In this case the needed bolts is M10x60mm (2pcs) and you can weld the nuts at the underside of holes. I used my 4x6 band saw to do this. This plate is a hardened abrasive resistant alloy. I cut the 1.5" angle down to 1". The angle iron is going to be straighter and truer than a 2x4. Just like a normal sheet bending machine. I used a router with a 1/4" round over on the top edge since the interior of the angle has a slight radius. The bender needs the ability to be adjusted up and down, then locked in place. Use your grinder gently without any haste and be sure, that your cuts are perpendicular. Safety Concerns:• Saws can cut you. Temporarily I decided to turn the brake by 135° so as to have more sharp bends. So for my need to build a stainless steel barbecue I decided to make a sheet metal bender brake. While it wasn't really necessary, I cut out the front face of the 2x4 so that the center plate would sit flush. And if you look at any folding machine you will see this feature. Overview: The 2x4 is the base that will be clamped to a workbench when the brake is in use. Van Mark Aluminum-Sheet Metal Brake Mark II 10' 6" (Leg Kit Sold Separately) 5 out of 5 stars (4) 4 product ratings - Van Mark Aluminum-Sheet Metal Brake Mark II 10' 6" (Leg Kit Sold Separately) Either way, nice build. Heavy gauge sheet is going to drive the price back up. Because of the rounded edges of the angled steel, I think it should be sharper so the metal has a cleaner edge when bending. While I don't need a metal brake often, it's good to have when needed. Did you make this project? Use a caliper or a vernier and mark a straight line at the entire length of the brake on both inner sides of angle-iron at 4mm from the corner. Cut the head from two hinge pivots, isn't needed. I used a jig saw angled to 45* to cut slots for the hinges in the 2x4. Sheet metal is used for car … The hold down needs a slot cut out not only for the hinge but for the hinge to bend back. Build a Sheet Metal Brake: I love building tools. 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. Align the siding's bend point with the hinged … Place the brake onto the brake's bed.Once again place the sheet metal strip 0.50mm from previous step, between bender and bed, but this time a little higher from the surface of bed/bender. Now I'm trying to come up with a project that requires metal! I used 2x4's clamped together prior to this. I've always wanted to build one but never found a design I liked that was easy to build. With the hold down slotted, I wanted a way to keep the hold down in place for a particular material thickness. Dec 15, 2013 - Explore Tony Petrzelka's board "Metal brake", followed by 129 people on Pinterest. Van Mark Aluminum-Sheet Metal Brake Mark II 10' 6" (Leg Kit Sold Separately) 5 out of 5 stars (4) 4 product ratings - Van Mark Aluminum-Sheet Metal Brake Mark II 10' 6" (Leg Kit Sold Separately) The tube will serve as handles, and I spaced them 24" apart. The other two angles were cut to 44" to reach the outside edge of each hinge. and complete my BBQ, leaving the correct solution ( a brake with sharpen edges) for a later time. This is what I designed and built, adding springs to make the hold down pop up and ensuring accurate adjustability for material thickness. While I only bought (2) angles, I did have to grind the rust and paint off the scrap angle. on Step 5. Until I experience the issue, I won' bother. Mount the brake in a flat and stable metal surface (in my case I have use my hydraulic portable table using two pieces of angle-iron (e.g. Stainless steel AISI 430 at foul width 800mm 0.50mm - 0.60mm - 0.70mm, Stainless steel AISI 304 at foul width 800mm 0.60mm -0.70mm - 0.80mm, Galvanized steel at width 500mm 0.90mm. Attach that to a drill. Clean up paint or rust of inner sides of angle iron about 10-15mm from corner so as to have a smooth and shiny surface. I always wanted a brake press in my workshop but I didn't want to shell out huge sums of money for a commercial one. Capacity, 60" Height, 21.5" Width, 20.5" Length 3.4 out of 5 … But isn't so big deal and can easily modified and be strengthened, avoiding the cracks at the ending of threads. The sheet metal brake is ready, has tested and is working. Thank you Kevanf1, you have put a lot of good work into your construction and Instructable. My hold down is slotted to adjust for the thickness of metal. I used the following items for this build: (1) 1/8″ x 1.5″ x 1.5″ x 4′ Steel Angle. I put the angle in place and marked the edges on the front face with a pencil. I clamp it down to a sturdy work bench when I use it. I cut my scrap steel angle, which will be the center plate, to 36" with the 4" hinges flanking it. I found this instructable very informative. I already had wire, using 18 gauge. I taped off what I needed to file out and used a round file to create the slot. A table saw cut the 2x4. If you have ever been into electronics, a problem often arises at the end of a project... “What the hell am I going to put all this in!! With the use of a center punch, do marks around the round bar and then press it, into the pipe. This is an excellent and worthy project, something I have often needed. There is 4" of 2x4 on each end for clamping. Aluminum bender/break made with simple hardware store supplies. Soon I will make an Instructable withthese modifications. Place another piece from the same sheet metal strip 0.50mm vertically onto the bed and between the brake and the first one. Nice. Thank you to 'kess_gr'. Angle grinder 115mm 4 ½” or 125mm 5” Angle grinder 180mm 7”, 2. $95.86 $ 95. 4.0 out of 5 stars 2. We will need a drill bit ø16mm and a piece of round bar ø16x65mm to fix this problem. Also if you interested to see some modifications of this brake;you can visit my instructable page "DIY Sheet Metal Brake Fully Modified". Maybe just weld a nut to the head of the clamp bolt and have another bolt screw through that for the adjustment? Working with sheet metal can be a rewarding, albeit sometimes frustrating, experience. I used a 1/8" metal bar to act as a spacer as I coiled the wire around the rod with a drill. In this case the needed bolts is M10x50mm (2pcs). Jan 15, 2019 - Explore Larry's board "Sheet metal brake" on Pinterest. The rugged steel construction of the bending brake allows it to bend metal up to 90 degree … but the top bar must be a 3mm thick bar). It might be a better idea for the line up adjustment to have slots for the bolts through the 2x4 and adjust them that way instead of on the angled clamp. Place and adjust the bushing bases to bed. Keep in place doing tacks to up/down side near the corners. Many thanks for doing this. This is how I made my home made box pan brake for a fraction of the cost of a shop bought version. The bending angle is what folds the metal. And since there is no table or bed on your bend, how do you manage to hold it down when bending the heavier gauge metals. I've made furniture, digital models, costumes, props, videos, graphics, animations, restored a vehicle, etc. I needed a triangular shape to facilitate the hold down sliding and to keep the washer in line. I love building tools. I used a jig saw to cut the slot in the wood and a file to true the corners. I like this one, but I'm not too sure about the angled clamp on top. The only change I would and could make is to try and flatten the hold down edges. I'll still be building one later this year :). Drill bits ø4mm ø8.5mm ø10mm ø16mm (ø8.5mm no needed if 11¹ exists), 1. The springs underneath were a result of testing it and having a hard time inserting the metal.I brain stormed through a few ideas for the adjustment and this made the most sense. Remember Safety First. The angle and hinges would have to be at different heights anyway to align so I left the top undisturbed. It hadn't been long that I made a spring jig and did a tutorial for spring making, so that worked perfectly. Has the advantage that can be mounted /dismounted, very quickly and operate at two positions, but has a very critical disadvantage: after some pressure the threads cracking next to Plumbing Tee. Later I will take the pin out of the hinge and flip the hinge so that the angles align. 30mm is the required space at each edge where would welded the pivots. It will break right off. While I could have tried to flush the top, I didn't want to run the risk of not getting the top flat. If you are using aluminum flashing, just clamp it in the blender and score it with a razor knife. I had already pulled the hinge pin out and flipped the hinges. Share it with us! The wood 2x4 is a black rubber under coat and everything else is gloss orange. I didn't want it taller than the hold down or to extend past the 2x4 base. The total height of grinding is 3mm but we need to make only 2.8mm leaving the rest 0.2mm for the final sharpening by file. Tape measure, Caliper optional but useful for the correct marking of the cuts, 10. There are two bolts in each handle with a 1/4" hole. 4.4 out of 5 stars 16. A brake is a metalworking machine that allows the bending of sheet metal. Having gone through the Instructable there certainly is provision for different thicknesses of material and they can be clamped down. 2pcs Bolts M10x50mm (or M10x60mm if 11¹ exists), 10. Each side is mitered at 45* the bottom is 1.25" wide and the top is 3/8" wide. I am always interested in such metal projects. They worked fine when centered inside the angle, but not when shifted. I didn't have cutting oil on hand so I used vegetable oil. However I would like to point out there has been no allowance made for different thickness materials. For a hold down you can use a 2x4 with steel strips under the front and back edges. The top plate front edge should be set back about 1/8 inch from the edge of the bottom plate (see photo). well it look,s easy now to convert to std measures meament,s will be good Awesome Build thks again. With my set up I have a greater degree of precision in setting it up. I got 1" which works, but I'd recommend at least a 1.25" length• (10) #10 Nuts - for hinges to bender and handles to bender• (16) 1" Drywall Screws - 4 in each hinge, 4 in the center plate, 2 in each adjustability angle. I have uploaded a new instructable and believe that can cover your needs. Doesn't matter, this was excellently done. All the measures for cuts start from the edges, so it doesn't matter the total length of the brake, Use the formulas below to calculate the desirable length for the bender and brake. Tightening the wing nuts would hold everything in place. Screwing/Unscrewing the Brake to Checking the Release System. FREE Shipping. wikipedia article: https://en.wikipedia.org/wiki/Brake_(sheet_metal_bending), 1. Adjust and do a tack weld at side of pivot and the top corner of angle-iron (point 1). The center of the hinge pin needs to center on the joint between the bending angle and base angle. DIY Sheet Metal Bending Tool || Sheet Metal Brake - YouTube Old bed frames are readlly available and could provide the perfect angle iron for this project. The heads are recessed with a 3/8" bit. and be adjacent to both sides of angle-iron. I preferred to slot as few components as possible. The adjustability bolts also work as intended. I also have a full face shield because I like my face and eyes. Originally they were much taller, but I had to cut them down after adding the spring perch. I'll take a look at the You Tube video to see the modifications. But nice instrucable - given me some great ideas. I left the surfaces that would contact the metal being bent unpainted as I figured it would just scuff the paint. Start grinding sliding the grinder gently from one end to other. I have a couple questions. DIY And Crafts. Optional rental … https://www.instructables.com/id/DIY-Sheet-Metal-B... Really? I usually have a respirator as most of my work involves cutting or sawing which generates dust I don't want to breath. If it's ok: proceed to welding. I could have used smaller screws • (4) #10 x 1-1/2" Flat Head Machine Screws - for handles to bender.I had planned on using 3/4" steel tube for the handles but ended up using 1" and didn't resize these screws. Please note: the hypotenuse of the triangle of an angle-iron 50x50mm is 71mm. 2pcs Spring coil ø2mm 4~5 turns, 7. What gauge metal can you bend with it? I used the hold down angle as a guide and drilled through the hinge and 2x4 and used a forstner bit on the bottom side of the 2x4 to recess the carriage bolt head. This leaves 2" on each end to clamp the 2x4 to a work bench. https://en.wikipedia.org/wiki/Brake_(sheet_metal_bending). Locking the clamping edge both verticaly and horozontaly will increase the consistency of your bends. Malco 52867 Leg Set with Bases and Fasteners. 4pcs Washers M10 (ø20/10.5) (or 8pcs if 11¹ exists), 11. Share it with us! At the moment it would bend very thin sheet but if a thicker sheet were attempted it would seize. Check to see if the center axis of pivots and the top corner of angle are inline. Thank you :), I am glad that my project is useful to you, and now you can restart.You can see some modifications about this brake in my youtube video. Always pay attention to how close your hands are to the blade and make sure you don't cut through anything unintended. All of the needed dimensions for the cuts, are described on the attached photos. Also allows one to form box and pan shapes digital models, costumes, props, videos graphics. Best performance bar ø16x65mm to fix this problem try to see the modifications no allowance made different. N'T as sharp as I coiled the wire around the rod with a hack and. Cm ) steel plate I bought flanking it hinge but for the final sharpening by.. 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