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Old 05-13-2015, 07:59 PM
septimus septimus is offline
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Default Tight Bend

I teach shop at a high school, but mostly machining. I'm trying to expand and do a little sheet metal work. So far the kids have made dustpans but they enjoyed that project and I'd like to work my way up to more than just basic bending. In the meantime, I found this set of plans for a few basic beginner projects. Here is the link:

http://www.shopnotes.com/files/issue...l-projects.pdf

I'm in the process of whipping up an example of the screwdriver rack but I can't figure out how to bend the 1 1/4 inch section. There isn't enough room in the brake to do this return bend. I thought I read a thread here once about doing a similar bend on the edge of an older pickup bed but I can't seem to find it.

Here's what the rack looks like:

Screen shot 2015-05-13 at 8.52.11 PM.jpg

Can anyone offer any advice on how to make this bend?

Thanks!
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Old 05-13-2015, 09:22 PM
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red baron red baron is offline
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Use some square tubing as a hammer form would be quick easy and reusable.
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Old 05-13-2015, 10:11 PM
JimRussell JimRussell is offline
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I think it was Richard K that suggested that you remove a few sections of fingers from your brake. Use the remaining fingers to hold down a piece of angle iron. Fold the center section over the angle iron.
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Old 05-14-2015, 03:44 AM
AllyBill AllyBill is offline
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That's just a 'top hat' stiffener with one flange deeper than the other. By doing the outer bends first and the central channel last that shape ought to come off a small box and pan folder fairly easily. Maybe play with some of the dimensions a little for best clearance.

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Old 05-14-2015, 04:48 AM
Dawnbringer Dawnbringer is offline
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Hi Stefan,

Try folding the 'Top' and 'Bottom' folds first (Meaning the fold that is the highest and lowest in the photo) TO ONLY about 15 - 30 degrees, but do this first. Then complete the other centre folds to 90 degrees. And then finish the 'Top' and 'Bottom' folds off last, and bring them to 90 degrees.

It should work, depending on the folder type that you are using of course.


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Mick

Last edited by Dawnbringer; 05-14-2015 at 05:04 AM.
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Old 05-14-2015, 05:00 AM
John Francis John Francis is offline
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Make it a 2 project project(???) and have the students make a small press brake: https://www.youtube.com/watch?v=mn1GsAJcpok You would possible have to finish two of the bends ( or at least one of them ) by hand , but it would give a nice bend to start with.( or cut a "window" in the top press plate to allow you to do a complete 90 deg. bend)
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Last edited by John Francis; 05-14-2015 at 05:49 AM. Reason: added info.
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Old 05-14-2015, 09:13 AM
bobadame bobadame is offline
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Change the design so that the piece could be made with a standard box and pan brake. The vertical flanges need to be short enough to fit in the space behind the bend shoes. Bend them first, then the inner bends. Punch the holes first while the piece is still flat.
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Old 05-14-2015, 10:12 AM
weldtoride weldtoride is offline
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Stefan, as a former shop teacher, I might share a trick I learned long ago for tight or complex bend proofing. Keep a supply of all your narrow drops from your shear handy, or even steel strap banding if you are short on drops, the bend sequence can then be tested and proofed without any material waste.
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Old 05-14-2015, 11:17 AM
septimus septimus is offline
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Thanks for all the suggestions! I'll play around with making this one work - I cut and punched holes in a few pieces to make a sample - but next I think I'll tweak the design a bit. Mark, thanks for the tip. I did try this out on a few narrow drops from the shear that's how I knew it would cause trouble. Small budgets mean I don't throw much away!
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Old 05-14-2015, 08:11 PM
mark g mark g is offline
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I remember having to make a part like this once on a press brake. We would make a temporary bend (maybe 30 degrees or less) in the middle of the 1-1/4" section to allow the other bends to be made, then flatten the temporary bend back out with firm pressure between two flat dies. Maybe you could adapt that thinking to your available tools.
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