Basic bending brakes typically retail for around $20-50, and are small enough to fit easily on most work benches or tabletops. A bending brake will be best suited for shaping flat, square sheets of light gauge aluminum. Heavy gauge aluminum bars or rods must be heat-bent using an acetylene torch and vice. This is a highly technical and potentially dangerous process best left to a professional metalworker. [1] X Research source
With the clamp bar in place, the two platforms that make up the frame of the brake should be positioned parallel to one another and overlap slightly.
To guarantee a straight, precise bend, examine your sheet to make sure the outer edge is running parallel to the edge of the clamp bar.
Some more expensive brake models have built-in clamps that can be applied by pulling down one or more handles. [5] X Research source The apron is the part of the brake that swings upwards to actually create the bend when you lift the handles.
If your brake has a stop bar, set it to the exact bend radius you want to achieve. It will stop the movement of the apron automatically once the sheet reaches a predetermined angle. [7] X Research source Don’t forget to undo the clamps and raise or lift off the clamp bar before removing your sheet from the brake.
Look for an inexpensive arbor press online, or at any hardware shop or specialty tool store that carries metalworking equipment. In many cases, you can find a brand new arbor press for as little as $50-70. [9] X Research source A standard arbor press is not much bigger than a coffee pot, which means it will fit comfortably in one corner of your work surface.
You can pick up an angle finder tool from any hardware store or home improvement center for around $20. Digital angle finders tend to be a little pricier, but they’re considerably more accurate than analogue tools, which could be important if your project calls for precision. [11] X Research source The exact bend radius you choose will depend on the nature of your project.
Fashioning a V-block will allow you to quickly and easily press your aluminum piece to just the right bend radius using the pre-measured angle inside the notch. A scrap 2x4 or 4x4 board will do just fine for most projects.
You can also use a scrap board, the spine of a book, or another flat, square object if you don’t have a ruler handy.
As a general rule, the pipe you use for your punch should be roughly twice the diameter as your desired bend radius. To form a 1⁄2 in (1. 3 cm) bend, for example, you’d need to use a 1 in (2. 5 cm) section of pipe. Construction sites, junkyards, and businesses that specialize in metalworking are all good places to scavenge for scrap steel. If you don’t have any luck there, you can also order the exact piece you need online. It’s important to use a pipe or rod made from steel, as it’s one of the only materials guaranteed to withstand the pressure exerted by the press.
If your aluminum piece isn’t centered inside the press, you could end up with a crooked or misplaced bend, effectively wasting your materials.
You may need to use both hands in order to generate enough force to bend the metal, depending on the thickness of your piece. Don’t forget that you can use your angle finder tool to confirm the precision of your work.
If you make a mistake, wipe off the marker with a small amount of rubbing alcohol and start over. Your bend line needs to be nice and straight in order for the bend itself to turn out the same way.
When selecting a suitable work surface, keep in mind that the friction of the metal could cause wear or more severe damage to wood and other soft materials.
An ordinary 2x4 will be perfect for most jobs, but you could also use a 2x6, 4x4, or another type of thick, heavy lumber. The most important thing is that it provide enough weight to anchor the sheet as you’re shaping it. [16] X Research source
Take a moment to lightly jostle the clamps and make sure they’re stable before proceeding. The shoe is the gripping surface located at the end of the screw, while the anvil is the gripping surface built into the arm of the clamp frame. [18] X Research source
If the piece you’re working with has sharp, thin, or jagged edges, it’s a good idea to wear a pair of rugged work gloves to protect yourself from accidental cuts. Tap the crease where the metal curves lightly with a rubber mallet to create a sharper bend. Manual bending works best for forming 90-degree angles, but you may also be able to produce other angles with steady pressure and a careful hand.
