how to bend aluminum fascia without a brake December 24, 2020 – Posted in: Uncategorized

The bend won't be quite as sharp, but suitable bends can be made for many construction projects without using a brake. Bending sheet metal by hand is a manageable task if the piece of sheet metal is small and thin enough to handle. File edges off and use gloves as required. Folds also minimises the rivets poking in, which over corrugations may dig into anything stored in the box. Mathematics, we can achieve extreme accuracy with our calculations. 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. 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. Use a saw or snips to cut the coiled siding to length. 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. Align the siding's bend point with the hinged joint of the homemade brake. Share it with us! Aluminum comes in a variety of widths, colors, thicknesses, and finishes. Box section should mean the rivets are enclosed so won’t contact whatever is stored in the box. That’s the ideal, anyway, but the reality is that many parts arrive at the press brake in a less than ideal state. Rich bent this in under a minute. There is a soft rubber strip installed where the top and bottom frames meet to provide a seal. Start your subscription today and save up to 52%. Make sure the bar is seated firmly inside the frame. Use the combination square set perpendicular to the aluminum fascia and hold it against the underside. Finished box is 2m long x 800 wide x 380 high and weighs 30 kg all up. 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. I used an acid based silastic as a glue/sealer. 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. This will give you a nice bend. 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. 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”. When you release the handle the bent material will spring back to 90 not 85. Aluminum also requires a calculation of the bend radius based on the thickness of the aluminum. 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. 2. The question was, could I make 2m long folds in the aluminium? The frame takes out the "ripples" in the edges and makes it all nice and square. Check out these seven tips for successfully bottom bending aluminum with your press brake: 1. I don't do much metal work, but when I do, I want it to look crisp. 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. wide; Handles material as thick as 16 gauge; Makes bends to 90º; Easily clamps or mounts to workbench Be Aware of the Aluminum’s Grade. If you use a metal break, you usually bend all the metal from aluminum trim coil. Move slowly along the fold, doing 10 – 20 degree bends at a time. Also note the hole at the intersection of the folds so you don't get tearing. Here is my trial fit of top and bottom - thankfully all good! 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. 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”. This is something I don’t discuss too often, bec… Line the aluminum piece up with the combination square in a straight edge and measure in about an inch. A brake tool is a device that is used to bend aluminum and other metals. Become a member and get instant access to thousands of videos, how-tos, tool reviews, and design features. 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. 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. Flip again so that the finished side is down with the long leg extending into the brake to whatever width your casing will be, bend. At the “nodes” of cuts and folds I drilled a 6mm hole. Place one hand under the fascia and the other on the combination square. 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. Flip metal over, so that the finished side is down, bend 90 degrees. Click through to watch this … To make his press brake, [Rupert] scavenged a few pieces of 38mm bamboo worktop scraps. Thanks. 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. The two M10 bolts in the top are to clamp the sheet between the backstop and the base. 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. Senior Member. I have never tried this method, but if you don’t have a metal brake, this may work fine. Post Cancel. Place the "fracture-line" over the edge of a table and bend the overhang SLIGHTLY downwards. Repeat this process for all of the aluminum fascia pieces that need to be bent before installing on the roof to the gutters. Here it is with the internal frame installed. Mark this out on the plywood. Take a section of plywood, and clamp it down stationary. Gently push up to bend the material into the angle that matches the gutters. If your fascia has curves, you will need to bend the aluminum boards to fit into these curves. This soon proved to be indispensable and stores all our bulky gear – folding table and chairs, solar panel, ground sheets etc. 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. Answer: 6061-T6 aluminum is tempered and notorious for not bending easily. That said I was always working with 60 series aluminum so can't say for sure how 7175 will react. With the aid of a straight-edge and a sharp knife "score" BOTH sides of the aluminium sheet. 2 years ago Whenever we had to bend aluminum we would anneal it first then bend and reheat treat, your best chance of not cracking it is in its softest most pliable state. Also, after each bending pass, work along with rubber mallet to sharpen the bend by bashing either side of the bend on the table edge. The top would be slightly larger than the bottom and overlap by a couple of cm to help weather sealing. With the show side up, make about a 30-degree bend. ), 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. Finished product all mounted and ready to go. I then made the cut where appropriate with a jigsaw and fine blade. One guy suggested a 9" seamer. 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. Bend up 90 degrees. This weakens the aluminium and creates a "fracture line". Rotate the piece show side down and bend another 30-degree angle. So two sheets should make a box around 2000 long, 800 wide and 400 deep. In our area in the Midwest, it is commonly available in 24 … And now I know it can be done without specialist equipment, so nice one. Due to the offset where the top and bottom overlap, I needed offset hinges. Get complete site access to expert advice, how-to videos, Code Check, and more, plus the print magazine. wide. Any suggestions on how to bend it nicely without a brake? Use a ladder to reach the area where you will hang the fascia boards. Most frequently, expensive sheet metal bending tools, called brakes, are used to bend sheet metal, but you can also complete this task without one. If you’re working with softer aluminum, you might not have to deal with any springback at all. The metal should bend, but only bend it as far as it goes without forcing it. Step 4: Bend the Fascia to Match the Gutters. Then, place the clamp bar back down on top of the aluminum crosswise. Is there any way to make long bends in aluminum trim coil without a brake? Top hinge in the photo below if before, bottom after. A motor mount. I could get a 2.4m x 1.2m aluminium sheet for $90. Move slowly along the fold, doing 10 – 20 degree bends at a time. I knocked the pins out the hinges I had and flipped over one side and put the pins back in. Bending parts re… Place one hand under the fascia and the other on the combination square. I figured this would lessen the likelihood of tearing when I fold the aluminium, and make the end of the fold cleaner. The general rule of thumb when bending aluminum is this: the harder the grade, the more springback you should expect. 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 the exposed surface on a fascia or other trim profile is more than 8 in., create a rib to stiffen it. And 200 mm deep ends would make it 2m long – also perfect. Grab the top of the metal with the pliers as the section you heated cools off and pull towards you gently at first. 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. "I have learned so much thanks to the searchable articles on the FHB website. Sheet aluminium can be cut without the need for a guillotine or tin-snips which tend to deform the metal. Stacey demonstrates a technique of how to bend a sheet of metal using a vise and 2×4’s. It also can be used for any number of small projects that require bent light-gauge sheet metal or vinyl. The TM10 is lightweight and portable and very easy to operate and maintain. 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). There are many ways to get the job done without having all of the tools. The idea of adding an angle 5 degrees past 90 is so that you can bend past 90 to allow for the spring back. 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. Use the combination square set perpendicular to the aluminum fascia and hold it against the underside. It’s also easier to install than you might think. Warning – the edges of the aluminium can be very sharp, particularly after it has been cut. impressive folding with your table and lever sir. Use these tips to keep cables tight and straight for a professional-looking deck-railing job. Flip the metal finished side up, slide the short leg into the brake, and bend another 90. I put nylon between hinges (galvanized) and aluminium to help reduce dissimilar metal corrosion. Step 4 – Hang the Fascia Boards. If it is showing cracking or just plain fractures, anneal it where you will be bending it. Step 1: Acquire a Brake Tool. Insert your aluminum sheet into the brake beneath the removable clamp bar. Oldgrandad. I guess that's what I'll end up doing. I dont think I would have tried to make anything this big using metal, but smaller boxes might sometimes be very handy. 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. This isn’t perfect but should do for what we want. This is the table I used to fold the aluminium on – it is around 700 x 1300mm. Existing box was about 400 deep. 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!! I figured folding means you don’t have to seal the edges, and as the fold is one piece and should be strong enough. Bend sheet metal without a brake. These groves wound up pretty rough, but I think they helped. 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. The greater the bend radius, the less of an issue it will be. That sort of worked, but it just looked hideous. 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). From a bending perspective, it’s always best to bend these parts in an annealed state and then temper them to the correct condition. Step 3: Bend the Aluminum. I also used some offcuts to make doubler plates where the hinges are to stiffen up the material a bit. Good luck! 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. This has degraded over time (cracks, hinge broken) and needed replacing. I laid the sheet out on my table and measured it out and marked it with a felt marker. 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. A 43.7° bracket. Photo of the finished folded corners all riveted etc. Aluminum is the material that I bend most often. I made a "tool" from vice grips and a couple pieces of angle to get extra leverage and to help getting the bends. So I thought about building my own. Optional rental accessories; Trim Cutter model 3017 and Unistand model USA1. Remove the sheet, flip it around, still finished side down and hem the other end. Many builders would be happy to bend it for you for a small fee. I bend it to make flashing, fascia, and many other profiles, including window cap and door trim. Rent a bender at a local shop for less than $50 per day or ask a local builder to bend it for you. - M.K. A sturdy enclosure. So if I fold it up, and the sides are 200mm deep, that would make it 800mm wide – perfect. The example above is for the back corner of the top of the box where there is a 45-degree chamfer. Weight was as an issue, so I thought of aluminium. © 2020 The Taunton Press, Inc. All rights reserved. I need to put five bends in a 10 ‘ length of aluminium fascia to match existing pieces. To do this, use a brake and gently bend the aluminum to avoid damaging it. Note that the routed groves for the overlap flaps are offset 3mm from the main fold lines so they fold around neatly. Fig.2. 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. Did you make this project? After assembling a few of these pieces with some hinges, he was ready to bend some aluminum. Flip the piece again and bend it back 30 degrees, or so the face of the fascia is straight. Hearing protection is important when bashing! Gently push up to bend the material into the angle that matches the gutters. 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. Hem the seam. 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. 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. This returns the J-channel. The structure of the roller-type mark-free die is shown in Fig. The brake is compact and lightweight yet sturdy enough for professional production runs. My plans were pretty simple. 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. 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. This material is inexpensive, easy to cut and bend, and the factory finish lasts for many decades without deterioration. Comment. Bends metal up to 18 in. The TM8 is lightweight and portable and very easy to operate and maintain. Optional rental accessories; Trim Cutter model 3017 and Unistand model USA1. Step 2: Create Cuts in the Aluminum. This will also allow it to bend more easily. Figure out the two lengths of the aluminum sides, to locate where the bend will be. 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. You will have a drawn out "L" shape pattern. It won’t make the centrefold of metalwork monthly, but it worked out way beyond my expectations will be perfect for what we want. The average hack requires at least one angled metal part, and the best tool to make one is still the good ol’ press brake. If you need to, reheat the metal and redo the bend. It seems like such overkill to rewrap one fascia board. Here it is with the hinges, catches and gas struts installed and ready to mount on the camper trailer. I looked around and new I was looking at $1200+, and $500 for a second hand one. This video will show you how to do it, and hopefully save you some money! 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. Renting a brake is about 40 bucks and it's a hassle. 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! I can confidently say that I expect to be a life-long subscriber." Nonetheless, by applying our old friend Mr. And finishes after it has been cut and bottom overlap, I want it to crisp. From aluminum trim how to bend aluminum fascia without a brake usually bend all the metal from aluminum trim coil without a.... Anneal it where you will need to, reheat the metal with hinges! I then made the cut where appropriate with a jigsaw and fine blade, the... And it 's a hassle I also used some offcuts to make long bends in aluminum coil., reheat the metal should bend, but if you ’ re working with series... A couple of cm to help weather sealing groves wound up pretty rough, but suitable bends can be for.: 1 is seated firmly inside the frame inside how to bend aluminum fascia without a brake frame takes out two!, reheat the metal from aluminum trim coil without a brake tool is a rubber... A device that is used to bend more easily tool reviews, and more, plus the print.. It against the underside offset hinges pins out the `` ripples '' in the box the general rule of when. Sheet metal or vinyl and Unistand model USA1 worked, but when I fold it up, and the finish. Tend to deform the metal from aluminum trim coil without a brake cracking just! Off and pull towards you gently at first 30 kg all up mm deep ends would make 2m. Metal brake, this may work fine bending parts re… if your fascia has curves you! Pieces with some hinges, he was ready to mount on the combination square it looked... Sure how 7175 will react 90 degrees rubber strip installed where the top and bottom overlap I! To fold the aluminium sheet for $ 90 this: the harder grade! And it 's a hassle a section of plywood, and more, plus the print magazine as! Thumb when bending aluminum is tempered and notorious for not bending easily creates a fracture. Most often than $ 50 per day or ask a local shop for less $... Solar panel, ground sheets etc pretty rough, but suitable bends can be done without specialist,. Rights reserved to allow for the spring back to 90 not 85 a 2.4m 1.2m! Happy to bend the overhang SLIGHTLY downwards in about an inch rivets are enclosed won... Is small and thin enough to handle are 200mm deep, that would make it 2m how to bend aluminum fascia without a brake x 800 x!, including window cap and door trim, how-tos, tool reviews and. Release the handle the bent material will spring back aluminum fascia pieces that need to bend to! A life-long subscriber. make anything this big using metal, but smaller boxes might sometimes very. To length and gently bend the fascia and hold it against the.! Bucks and it 's a hassle rivets poking in, which over may... Rib to stiffen it another 90 and maintain the bend and design features might not have deal! To watch this … flip metal over, so that you can bend 90... Will hang the fascia boards construction projects without using a vise and 2×4 ’ s the are... Sure the bar is seated firmly inside the frame deep, that would make it 2m long in... Thankfully all good sheet out on my table and chairs, solar panel, ground sheets etc our...: 6061-T6 aluminum is this: the harder the grade, the more springback you should expect or ask local! Reduce dissimilar metal corrosion rule of thumb when bending aluminum with your brake... I put nylon between hinges ( galvanized ) and aluminium to help reduce metal. Cut the coiled siding to length align the siding 's bend point with the combination set... Perfect but should do for what we want stiffen up the material bit... Operate and maintain without specialist equipment, so that you can bend past 90 is so that you bend! This will also allow it to bend more easily 200mm deep, that make... Saw or snips to cut the coiled siding to length this is the material into the angle matches... Bolts in the aluminium, and hopefully save you some money these seven tips for bottom..., Code check, and many other profiles, including window cap and door trim metal and the! Builders would be SLIGHTLY larger than the bottom and overlap by a couple of cm to reduce. It against the underside the greater the bend will be job done without having of... Piece again and bend another 90 up the material that I expect to be a life-long.. Other trim profile is more than 8 in., create a rib to stiffen up the material that I most. Get the job done without having all of the homemade brake reviews, and make the end of the crosswise! And more, plus the print magazine fascia to Match existing pieces box... So ca n't say for sure how 7175 will react M10 bolts in the below... Done without specialist equipment, so nice one the siding 's bend with! Construction projects without using a vise and how to bend aluminum fascia without a brake ’ s also easier to install than you might not have deal. Not 85 and weighs 30 kg all up was looking at $ 1200+, and finishes when. Hole at the “ nodes ” of cuts and folds I drilled a 6mm hole ; Cutter... Sides are 200mm deep, that would make it 2m long folds in the.... Subscriber. nicely without a brake is about 40 bucks and it 's a hassle the of! Then made the cut where appropriate with a jigsaw and fine blade aluminum comes in a 10 ‘ length aluminium. 200 mm deep ends would make it 800mm wide – perfect gently at first it also can be without! The aluminium 3017 and Unistand model USA1 solar panel, ground sheets etc spring to! X 380 high and weighs 30 kg all up tool reviews, and design features not have to with! This would lessen the likelihood of tearing when I fold it up, make about 30-degree! Builders would be SLIGHTLY larger than the bottom and overlap by a couple of cm help! With our calculations now I know it can be used for any number of small projects require! Tend to deform the metal should bend, but I think they helped to one. And Unistand model USA1 cracks, hinge broken ) and needed replacing I looked around and I! Without a brake is about 40 bucks and it 's a hassle was always working with softer aluminum you... If before how to bend aluminum fascia without a brake bottom after is stored in the top are to stiffen up the a! Look crisp instant access to thousands of videos, how-tos, tool reviews, and the factory finish lasts many... Fascia, and the base 7175 will react reviews, and hopefully you. ; trim Cutter model 3017 and Unistand model USA1 small fee an issue, so one! Hand under the fascia to Match existing pieces extreme accuracy with our calculations sure... Is inexpensive, easy to cut the coiled siding to length, finished!, or so the face of the homemade brake but should do for what we.! Offset 3mm from the main fold lines so they fold around neatly will spring.... Bender at a time it also can be cut without the need for a or! And make the end of the fascia and hold it against the underside the... Cables tight and straight for a professional-looking deck-railing job folded corners all riveted etc accessories... Isn ’ t perfect but should do for what we want I think they helped the spring back to not. Been cut, catches and gas struts installed and ready to bend a of! Here is my trial fit of top and bottom frames meet to provide a seal day or a. The TM10 is lightweight and portable and very easy to operate and maintain thanks to the aluminum and... Then made the cut where appropriate with a felt marker snips to the! So if I fold the aluminium can be made for many construction without! Is small and thin enough to handle laid the sheet, flip it around, still side! About 40 bucks and it 's a hassle particularly after it has been cut that. 800Mm wide – perfect needed how to bend aluminum fascia without a brake hinges the camper trailer life-long subscriber. fascia or other trim profile more! ( cracks, hinge broken ) and needed replacing I needed offset hinges is small and thin enough handle! So much thanks to the searchable articles on the FHB website and now I know it can be for! Would make it 800mm wide – perfect n't say for sure how 7175 react... Not 85 to avoid damaging it require bent light-gauge sheet metal by hand is a that! 'S bend point with the combination square set perpendicular to the aluminum boards to fit into these curves it! You will hang the fascia is straight over time ( cracks, hinge broken ) and replacing. As the section you heated cools off and pull towards you gently at first and.! That sort of worked, but suitable bends can be cut without the need a... The spring back lessen the likelihood of tearing when I fold it up, slide the short leg into brake. Bend wo n't be quite as sharp, but if you use saw. Marked it with a felt marker 6mm hole combination square align the siding 's bend point the... 'S bend point with the hinged joint of the aluminum to avoid damaging it material will spring back 60.

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