Bending small aluminium sheets

[Dunc]

I have some small aluminium sheets 2mm thick about 200mm x 75mm. I want to make it into an L-shape with the bend paralell to the long side and the tail being about 20mm (to make a cosmetic capping for a couple of corners). Any tips and tricks?

 

An initial attempt with the sheet clamped to a bit of 2x4 required a mallet to bend it - I'm not strong enough to make it bend by hand. The radius is a little large, but acceptable. However it's difficult to create a flat surface having battered it with a mallet - there are a few bulges where it doesn't sit quite flat.

 

 

[SimonD]

You really need a bending press or folder to get a proper finish in these kinds of things. If you're only doing a few, I'd recommend nipping down to your local metals supply place, ask to buy some off cuts and then bung them a few quid to shear and bend it all to your needs. They're usually happy to do this kind of thing. Once or twice I've also just nipped into a sheet metal fabricators and asked them if they have a few minutes spare. Never been turned away yet and you get quality.

 

 

[JohnMo]

48 minutes ago, Dunc said:

to make a cosmetic capping for a couple of corners). Any tips and tricks?

Buy the correct aluminium capping pre made. You will not get a sharp bend without a proper bender, and depending on grade of aluminium it may crack.

[torre]

With the caveat that everyone's 'acceptable' varies, I've done similar in the past by clamping the tail in a workmate, so the whole edge is held securely against something with a small radius, then using a sheet of ply to apply an even force to the rest of the aluminium, ideally limiting how far the bottom of that ply can move away from the aluminium. 

 

Main thing is to be clamping the smaller side and working the larger side.

 

I agree this is no substitute for paying for fabrication of course and you need to be sure you're not going to do more expensive damage than you might be saving

[Russell griffiths]

2mm is far too thick to diy bend without the correct gear, either get some thinner material or just buy a pre bent piece. 
Most roof materials are well under 1mm

the only thing I have in metal thicker than 1mm are the window cills and they are probably only 1.5mm. 

[markc]

At 200mm long you can do it in a decent size vice with 2 pieces of angle to act like a press brake. Bit fiddly to hold until you get vice nipped but it does work. 40x40x3 angle would be upto this. Possibly 25x25 angle as your piece is only 60mm wide

Edited 1 hour ago by markc