DIY Sheet Metal Folder

[Onoff]

I need to fold a bit of stainless to mount a doorbell camera in my gate pillar. Made one housing but not happy with the result of beating it over in the vice so decided to make a folder/brake press. I could do with one for some other bits I've got to make anyway. A case of what have I got lying around!

 

A bit of 150x75 PFC, galvanised:

 

 

Some 50x50x6 RSA:

 

 

Some random, heavy wall steel tube. Plenty of bits of this and box about:

 

 

I had intended to use weld on "pinet" hinges (from RS) but they are a bit lightweight perhaps. I've already started discing out the steel to fit these hinges. The axis of the hinge needs to be dead centre to where the top of the (mitred) RSA and PFC meet:

 

 

Was struggling anyway with which way up to put the hinges. They've this odd "pointy" side to apparently make alignment against a straight edge easier. Reckon I'd be better off with plain, circular hinges:

 

 

 

Plan was today then was to mark up and disc out for 33.7 OD hinges made from some old handrail off cuts:

 

 

The tube ID is nom 27.7mm (3mm wall). All I have for hinge pins is some 25mm, 80mm long stainless shafts, or a short length of 1" ali.

 

 

 

Whoops! Just realised the effective working length of this bender will only be about 400mm! OK for what I immediately want it for, to remake this:

 

 

No good though when I come to remake my boiler top. Done by hand last time, edges beaten over clamped wood:

 

 

I've cut my losses and stopped now. I've access to some longer channel I think so I'll get that.

 

 

[gaz_moose]

if your going to use a length of angle for the top beam then weld a length of flat in the Vee for added strength, same for your hinged part.

 

you will soon hate this type of folder and wish you had a box pan folder instead.

Edited July 27, 2021 by gaz_moose
addition.

[Onoff]

15 minutes ago, gaz_moose said:

if your going to use a length of angle for the top beam then weld a length of flat in the Vee for added strength, same for your hinged part.

 

you will soon hate this type of folder and wish you had a box pan folder instead.

 

I'll be bracing with 1" box section. Cos I've got stacks of it.

 

As I have f**k all at the moment in the way of a folder, anything will be better than beating sheet with a hammer! ?

Edited July 27, 2021 by Onoff

[Onoff]

All change. I ditched the shop bought pinet hinges and made some on the lathe out of a couple of 8.8 bolts:

 

 

 

 

 

 

A bit of fettling of the angle and channel before I weld them on.

 

 

 

[dnb]

It's looking good so far. You could borrow mine should you stray this side of the solent for a summer break and need to display some forward progress. It's the same basic design, and yes there are better designs... I would avoid box section for the top clamp since you'll need to bend pieces more than 90 degrees - triangles are the way forward.

[Onoff]

1 hour ago, dnb said:

It's looking good so far. You could borrow mine should you stray this side of the solent for a summer break and need to display some forward progress. It's the same basic design, and yes there are better designs... I would avoid box section for the top clamp since you'll need to bend pieces more than 90 degrees - triangles are the way forward.

 

Ah the IoW, that exotic destination from better times! ? Won't be going anywhere this year, especially as SWMBO hasn't had her jabs yet. FINALLY coming round to the idea mind.

 

What arrangement have you done for your pivot? I was half thinking instead of the home made 10mm, high temsile pins above, to say weld plates on the end of the channel with holes in. Then weld round bar say 24mm dia to just the angle. 24mm round bar sits in holes in the channel's end plates.

 

I'm using angles but going to reinforce them with 1" box behind.

 

Cheers

Edited July 28, 2021 by Onoff

[gaz_moose]

do them like in your picture with the pointing finger. do the top beam out of Angle but with the corner of the angle facing upwards. you might have to grind the edges down so it sits flat. this will allow you to bend over 90 degrees.