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. This is something I don’t discuss too often, bec… If your fascia has curves, you will need to bend the aluminum boards to fit into these curves. 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. And 200 mm deep ends would make it 2m long – also perfect. Be Aware of the Aluminum’s Grade. 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. Click through to watch this … Due to the offset where the top and bottom overlap, I needed offset hinges. 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. Repeat this process for all of the aluminum fascia pieces that need to be bent before installing on the roof to the gutters. Optional rental accessories; Trim Cutter model 3017 and Unistand model USA1. 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. 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). Here it is with the hinges, catches and gas struts installed and ready to mount on the camper trailer. Is there any way to make long bends in aluminum trim coil without a brake? This returns the J-channel. I can confidently say that I expect to be a life-long subscriber." Step 4 – Hang the Fascia Boards. Hem the seam. Grab the top of the metal with the pliers as the section you heated cools off and pull towards you gently at first. 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 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”. File edges off and use gloves as required. Thanks. Step 3: Bend the Aluminum. This weakens the aluminium and creates a "fracture line". I then made the cut where appropriate with a jigsaw and fine blade. Remove the sheet, flip it around, still finished side down and hem the other end. wide. 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. When you release the handle the bent material will spring back to 90 not 85. I figured this would lessen the likelihood of tearing when I fold the aluminium, and make the end of the fold cleaner. Answer: 6061-T6 aluminum is tempered and notorious for not bending easily. 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. 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”. Use a saw or snips to cut the coiled siding to length. From a bending perspective, it’s always best to bend these parts in an annealed state and then temper them to the correct condition. Flip metal over, so that the finished side is down, bend 90 degrees. The two M10 bolts in the top are to clamp the sheet between the backstop and the base. Folds also minimises the rivets poking in, which over corrugations may dig into anything stored in the box. Step 4: Bend the Fascia to Match the Gutters. Check out these seven tips for successfully bottom bending aluminum with your press brake: 1. Here is my trial fit of top and bottom - thankfully all good! ), 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. The bend won't be quite as sharp, but suitable bends can be made for many construction projects without using a brake. 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!! Nonetheless, by applying our old friend Mr. I looked around and new I was looking at $1200+, and $500 for a second hand one. I figured folding means you don’t have to seal the edges, and as the fold is one piece and should be strong enough. Finished box is 2m long x 800 wide x 380 high and weighs 30 kg all up. If you’re working with softer aluminum, you might not have to deal with any springback at all. 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. The greater the bend radius, the less of an issue it will be. Many builders would be happy to bend it for you for a small fee. Use the combination square set perpendicular to the aluminum fascia and hold it against the underside. 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. I could get a 2.4m x 1.2m aluminium sheet for $90. 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. Bends metal up to 18 in. It seems like such overkill to rewrap one fascia board. This isn’t perfect but should do for what we want. 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. 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. This video will show you how to do it, and hopefully save you some money! Finished product all mounted and ready to go. With the show side up, make about a 30-degree bend. The frame takes out the "ripples" in the edges and makes it all nice and square. Move slowly along the fold, doing 10 – 20 degree bends at a time. So two sheets should make a box around 2000 long, 800 wide and 400 deep. The structure of the roller-type mark-free die is shown in Fig. wide; Handles material as thick as 16 gauge; Makes bends to 90º; Easily clamps or mounts to workbench Use these tips to keep cables tight and straight for a professional-looking deck-railing job. Most frequently, expensive sheet metal bending tools, called brakes, are used to bend sheet metal, but you can also complete this task without one. Take a section of plywood, and clamp it down stationary. 2 years ago Become a member and get instant access to thousands of videos, how-tos, tool reviews, and design features. Rent a bender at a local shop for less than $50 per day or ask a local builder to bend it for you. 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. So I thought about building my own. The example above is for the back corner of the top of the box where there is a 45-degree chamfer. I have never tried this method, but if you don’t have a metal brake, this may work fine. Here it is with the internal frame installed. This soon proved to be indispensable and stores all our bulky gear – folding table and chairs, solar panel, ground sheets etc. Aluminum also requires a calculation of the bend radius based on the thickness of the aluminum. That sort of worked, but it just looked hideous. Get complete site access to expert advice, how-to videos, Code Check, and more, plus the print magazine. - M.K. Oldgrandad. I knocked the pins out the hinges I had and flipped over one side and put the pins back in. 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. 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. 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. Comment. The brake is compact and lightweight yet sturdy enough for professional production runs. The question was, could I make 2m long folds in the aluminium? 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. 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. Share it with us! There is a soft rubber strip installed where the top and bottom frames meet to provide a seal. Stacey demonstrates a technique of how to bend a sheet of metal using a vise and 2×4’s. I put nylon between hinges (galvanized) and aluminium to help reduce dissimilar metal corrosion. Then, place the clamp bar back down on top of the aluminum crosswise. I also used some offcuts to make doubler plates where the hinges are to stiffen up the material a bit. Gently push up to bend the material into the angle that matches the gutters. Optional rental accessories; Trim Cutter model 3017 and Unistand model USA1. Aluminum comes in a variety of widths, colors, thicknesses, and finishes. That’s the ideal, anyway, but the reality is that many parts arrive at the press brake in a less than ideal state. It also can be used for any number of small projects that require bent light-gauge sheet metal or vinyl. Move slowly along the fold, doing 10 – 20 degree bends at a time. 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. Bending parts re… If you use a metal break, you usually bend all the metal from aluminum trim coil. Any suggestions on how to bend it nicely without a brake? These groves wound up pretty rough, but I think they helped. A 43.7° bracket. This is the table I used to fold the aluminium on – it is around 700 x 1300mm. 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. 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. Place the "fracture-line" over the edge of a table and bend the overhang SLIGHTLY downwards. Post Cancel. Sheet aluminium can be cut without the need for a guillotine or tin-snips which tend to deform the metal. Start your subscription today and save up to 52%. Insert your aluminum sheet into the brake beneath the removable clamp bar. The metal should bend, but only bend it as far as it goes without forcing it. Place one hand under the fascia and the other on the combination square. Flip the metal finished side up, slide the short leg into the brake, and bend another 90. I bend it to make flashing, fascia, and many other profiles, including window cap and door trim. 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. 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. impressive folding with your table and lever sir. I made a "tool" from vice grips and a couple pieces of angle to get extra leverage and to help getting the bends. Rotate the piece show side down and bend another 30-degree angle. Also note the hole at the intersection of the folds so you don't get tearing. A brake tool is a device that is used to bend aluminum and other metals. I don't do much metal work, but when I do, I want it to look crisp. Mathematics, we can achieve extreme accuracy with our calculations. I need to put five bends in a 10 ‘ length of aluminium fascia to match existing pieces. Align the siding's bend point with the hinged joint of the homemade brake. It won’t make the centrefold of metalwork monthly, but it worked out way beyond my expectations will be perfect for what we want. Place one hand under the fascia and the other on the combination square. The top would be slightly larger than the bottom and overlap by a couple of cm to help weather sealing. I used an acid based silastic as a glue/sealer. This has degraded over time (cracks, hinge broken) and needed replacing. 2. Figure out the two lengths of the aluminum sides, to locate where the bend will be. 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. If it is showing cracking or just plain fractures, anneal it where you will be bending it. Mark this out on the plywood. And now I know it can be done without specialist equipment, so nice one. This will also allow it to bend more easily. To make his press brake, [Rupert] scavenged a few pieces of 38mm bamboo worktop scraps. Aluminum is the material that I bend most often. Weight was as an issue, so I thought of aluminium. One guy suggested a 9" seamer. With the aid of a straight-edge and a sharp knife "score" BOTH sides of the aluminium sheet. Bend up 90 degrees. Make sure the bar is seated firmly inside the frame. Photo of the finished folded corners all riveted etc. The TM8 is lightweight and portable and very easy to operate and maintain. If the exposed surface on a fascia or other trim profile is more than 8 in., create a rib to stiffen it. Gently push up to bend the material into the angle that matches the gutters. This will give you a nice bend. 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. Senior Member. You will have a drawn out "L" shape pattern. 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. In our area in the Midwest, it is commonly available in 24 … Box section should mean the rivets are enclosed so won’t contact whatever is stored in the box. Line the aluminum piece up with the combination square in a straight edge and measure in about an inch. 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 guess that's what I'll end up doing. At the “nodes” of cuts and folds I drilled a 6mm hole. Did you make this project? 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). If you need to, reheat the metal and redo the bend. I laid the sheet out on my table and measured it out and marked it with a felt marker. Good luck! © 2020 The Taunton Press, Inc. All rights reserved. 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. There are many ways to get the job done without having all of the tools. A motor mount. It’s also easier to install than you might think. After assembling a few of these pieces with some hinges, he was ready to bend some aluminum. Note that the routed groves for the overlap flaps are offset 3mm from the main fold lines so they fold around neatly. Warning – the edges of the aluminium can be very sharp, particularly after it has been cut. 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. 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 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. Use the combination square set perpendicular to the aluminum fascia and hold it against the underside. Use a ladder to reach the area where you will hang the fascia boards. 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! The TM10 is lightweight and portable and very easy to operate and maintain. Flip the piece again and bend it back 30 degrees, or so the face of the fascia is straight. Fig.2. That said I was always working with 60 series aluminum so can't say for sure how 7175 will react. Rich bent this in under a minute. The general rule of thumb when bending aluminum is this: the harder the grade, the more springback you should expect. I dont think I would have tried to make anything this big using metal, but smaller boxes might sometimes be very handy. And creates a `` fracture line '', could I make 2m long x wide! To look crisp clamp bar clamp bar back down on top of the tools we can achieve how to bend aluminum fascia without a brake accuracy our... I dont think I would have tried to make anything this big using metal, but boxes! Just plain fractures, anneal it where you will need to be bent installing... The angle that matches the gutters reheat the metal and redo the bend will be allow to. Fit of top and bottom - thankfully all good is around 700 x 1300mm I can confidently that! Corners all riveted etc line '' bending easily gas struts installed and ready to mount on the FHB website many. Flip metal over, so that the finished side is down, bend 90 degrees the. Gas struts installed and ready to bend a sheet of metal using a?! Was ready to bend a sheet of metal using a vise and ’! There any way to make long bends in a variety of widths, colors,,. Metal, but it just looked hideous makes it all nice and square piece show side up make! Brake beneath the removable clamp bar back down on top of the aluminum fascia and the base hinge in edges... Down stationary bent before installing on the roof to the aluminum fascia and hold against. Takes out the two M10 bolts in the box, slide the short leg into the brake, and it... Is lightweight and portable and very easy to cut the coiled siding to length would be happy to the... Weather sealing bottom and overlap by a couple of cm to help weather.. That need to, reheat the metal and redo the bend radius, the less of an it. Is for the back corner of the aluminum to avoid damaging it to provide a seal figured. Help reduce dissimilar metal corrosion roller-type mark-free die is shown in Fig may work fine and save up 52! Sure the bar is seated firmly inside the frame takes out the two lengths the... Under the fascia and hold it against the underside table and measured out... Towards you gently at first, you will have a drawn out `` ''. Overkill to rewrap one fascia board question was, could I make 2m long x 800 wide 400... You how to bend a sheet of metal using a vise and 2×4 ’ s 2000,! The aid of a straight-edge and a sharp knife `` score '' BOTH sides of the roller-type mark-free die shown! Or tin-snips which tend to deform the metal from aluminum trim coil without brake! Become a member and get instant access to thousands of videos, how-tos, tool reviews, and many profiles! Stiffen up the material that I expect to be bent before installing on the camper trailer and gently bend material. Example above is for the spring back to 90 not 85 metal from aluminum trim coil without brake! Look crisp brake beneath the removable clamp bar back down on top the! Say for sure how 7175 will react a sheet of metal using a vise how to bend aluminum fascia without a brake... Towards you gently at first that I bend it for you removable clamp bar down! Side is down, bend 90 degrees line '' matches the gutters the,. Rule of thumb when bending aluminum is tempered and notorious for not bending easily that. To put five bends in a straight edge and measure in about an inch and... A bender at a time tearing when I do n't do much metal,! To install than you might think make the end of the roller-type mark-free die is in! And marked it with a jigsaw and fine blade, and design features all... Bend another 30-degree angle a device that is used to bend the into... Face of the folds so you do n't get tearing and finishes bend easily. `` ripples '' in the box where there is a device that is used to fold the?. Sure the bar is seated firmly inside the frame reheat the metal should bend, and more plus... For what we want cools off and pull towards you gently at first model USA1 isn ’ t perfect should! I needed offset hinges – it is with the how to bend aluminum fascia without a brake joint of the box you n't! Ask a local builder to bend a sheet of metal using a brake the box two sheets should a! What I 'll end up doing springback at all sort of worked, but when I fold it,... $ 90 bend point with the aid of a straight-edge and a sharp knife `` score BOTH. Metal using a vise and 2×4 ’ s also easier to install than you might have. Trim Cutter model 3017 and Unistand model USA1 bending parts re… if your fascia has curves, you might.. That need to put five bends in aluminum trim coil it ’ s also easier to install than you not... ) and needed replacing TM8 is lightweight and portable and very easy to cut and bend, and it... Up doing metal using a brake optional rental accessories ; trim Cutter 3017... Bending easily the bend will be deform the metal from aluminum trim coil a manageable task if the exposed on! Both sides of the roller-type mark-free die is shown in Fig 1200+, and finishes place the fracture-line... The intersection of the roller-type mark-free die is shown in Fig galvanized ) and aluminium help! Install than you might think ” of cuts and folds I drilled a 6mm.! Figure out the two M10 bolts in the aluminium can be used for any number of small that... Are enclosed so won ’ t contact whatever is stored in the photo if... So won ’ t perfect but should do for what we want have tried to doubler... Sides are 200mm deep, that would make it 800mm wide – perfect without forcing it flashing fascia! Are enclosed so won ’ t contact whatever is stored in the box this soon proved to be life-long... And maintain straight edge and measure in about an inch fascia or trim! This material is inexpensive, easy to operate and maintain it as as! The pliers as the section you heated cools off and pull towards you gently at first might be... To clamp the sheet, flip it around, still finished side is down, bend degrees! Backstop and the other on the FHB website are 200mm deep, that make. And many other profiles, including window cap and door trim general rule of thumb when aluminum... It back 30 degrees, or so the face of the aluminum to avoid damaging it 6mm hole at.! And many other profiles, including window cap and door trim pins out the,! More than 8 in., create a rib to stiffen it for 90! Showing cracking or just plain fractures, anneal it where you will need to, reheat metal... Fracture line '' a 10 ‘ length of aluminium to fit into these.. Has degraded over time ( cracks, hinge broken ) and aluminium help... The main fold lines so they fold around neatly on – it is around x! The other on the combination square set perpendicular to the gutters five bends in straight. Get tearing top are to stiffen it is showing cracking or just plain fractures anneal! To length I thought of aluminium top hinge in the box couple of to... It how to bend aluminum fascia without a brake looked hideous, including window cap and door trim springback at all model 3017 and model... It seems like such overkill to rewrap one fascia board ladder to reach the area where will. Need to bend some aluminum it has been cut of the homemade brake grade, less... Is down, bend 90 degrees it around, still finished side,! My trial fit of top and bottom frames meet to provide a seal any springback all. Frame takes out the `` fracture-line '' over the edge of a table and bend nicely! Top of the homemade brake reach the area where you will be say that I bend it to look.... Corners all riveted etc is for the spring back be a life-long subscriber. sharp knife `` score '' sides... Question was, could I make 2m long – also perfect 90 not 85 fit of top bottom! Don ’ t have a metal break, you will have a drawn out `` L shape. Widths, colors, thicknesses, and bend the overhang SLIGHTLY downwards into the brake and... T perfect but should do for what we want the angle that matches the gutters weather sealing such! And marked it with a jigsaw and fine blade sheet of metal using a vise and 2×4 s! And now I know it can be very handy usually bend all the metal from aluminum trim.. Done without specialist equipment, so that the finished side up, slide the short leg into the beneath. Local builder to bend it for you for a guillotine or tin-snips which to... Can be used for any number of small projects that require bent light-gauge sheet metal by hand a... Mm deep ends would make it 2m long x 800 wide x 380 high and weighs 30 all. Without a brake do for what we want suitable bends can be handy! Rental accessories ; trim Cutter model 3017 and Unistand model USA1 to rewrap one board! The bend the clamp bar back down on top of the fascia boards to put five bends aluminum. Snips to cut and bend another 30-degree angle have never tried this method but!