If you need to bend aluminum for a repair job, crafting project, or similar task, you can learn how to do it.Depending on the form you are working with, there are a couple standard ways of bending aluminum.If you want to bend large sheets, the best bet is to use a metal bending brake, or to make your own with a sturdy table and some scrap wood.An arbor press will get the job done in a clean, precise manner for small or irregularly shaped pieces.
Step 1: Purchase a metal bending brake at a hardware store.
A bending brake is a specialized tool used to create precise linear bends and folds in light gauge sheet metals.One of the platforms is fixed and the other is open.Pulling up on a pair of small handles causes the platform to move upwards, bending the metal at different angles to the fixed platform.Basic bending brakes retail for around $20-50 and are small enough to fit on most work benches.The best way to shape light gauge aluminum is with a bending brake.Heavy gauge aluminum bars or rods must be heat-bent.It is best to leave this process to a professional metalworker.
Step 2: Attach the aluminum sheet to the brake.
Lift the bar away from the rear of the brake frame and slide the sheet in a certain direction to bend it.Put the bar back on top of the aluminum.The bar needs to be firmly seated inside the frame.The two platforms that make up the frame of the brake should be positioned parallel to one another.
Step 3: Set your bend line by adjusting the edge of your sheet.
Move the sheet around inside the brake to align the bend point with the internal edge of the bar.The bend will be produced by the folded section of the sheet beneath the bar.To guarantee a straight bend, make sure the outer edge is parallel to the edge of the bar.
Step 4: Attach a pair of C-clamps.
If you want to screw the bar clamp down tight, position it an equal distance from either end.There is no need to place the clamps over the aluminum itself.They cinch the bar to the apron of the brake.The built-in clamps that can be applied by pulling down one or more handles are found in some more expensive brake models.The apron is the part of the brake that swings upwards when you lift the handles.
Step 5: To bend your sheet, lift the handles of the apron.
sheet aluminum is very soft, so you won't need to use a lot of force.The sheet will be folded around the edge of the bar when the apron comes up.Pull up on the handles until you get the shape you want.If your brake has a stop bar, make sure you set it to the bend radius you want.Once the sheet reaches a preset angle, it will stop the movement of the apron.Lift or raise the bar to remove the sheet from the brake.
Step 6: Purchase or rent an arbor press at a home improvement center.
An arbor press is a type of press used to install and shape small pieces of metal.The table plate, anvil, and hand lever are the basic components of an arbor press.You can find an arbor press online or at a specialty tool store that carries metalworking equipment.A brand new arbor press can be found for as little as $50-70.A standard arbor press is small enough to fit in one corner of your work surface.
Step 7: The angle finder can be used to set the bend radius.
A lot of angle finders have two short legs that are independent of one another.There are markings on each leg that show different angles in relation to the opposing leg.Move the legs to the angle you need.You can find angle finder tools at any hardware store or home improvement center.Digital angle finders are more accurate than analogue tools, which could be important if your project calls for precision.The nature of your project will affect the bend radius you choose.
Step 8: Use a piece of wood to cut your bend radius.
Once you have determined the bend radius for your project, mark the angle onto the vertical edge of the wood.To remove excess wood from the marking, use a table saw, miter saw or circular saw.The V-shaped grooves in the center of the solid block will be used to shape your aluminum piece.A V-block will allow you to quickly and easily press your aluminum piece to the right bend radius using the pre-measured angle inside the notch.Most projects can be done with a scrap 2x4 board.
Step 9: If you want to bend the piece, draw a line on the surface.
Grab a ruler, align one edge with your chosen bend site, and run a felt-tipped marker or similar writing utensil down the edge.Make your bend line bold and dark to make it visible during the shaping process.If you don't have a ruler, you can use a scrap board, the spine of a book, or another flat object.
Step 10: Place a piece of steel pipe over the bend line.
The bend line on the face of the aluminum should be aligned with the pipe.If you want it to be secure, apply as many strips of tape as you can.You will bend your piece with the help of this pipe.The pipe you use for your punch should be twice the diameter as you want.A section of pipe is needed to form a 2 in bend.You can find scrap steel at construction sites, junkyards, and businesses that specialize in metalwork.You can also order the exact piece online if you don't have any luck there.Steel is one of the only materials guaranteed to survive the pressure exerted by the press.
Step 11: Place your piece in the arbor press by centering it on the V-block.
Put the block inside the press with the anvil over the pipe.Double-check the punch pipe's position in relation to the anvil of the press and the notch.You will be ready to bend your piece when you are certain that they are all lined up squarely.If your piece isn't centered inside the press, you could end up with a crooked or misplace bend.
Step 12: Pull the lever to lower the anvil.
The punch pipe will be pressed into the aluminum at the bend line as the lever goes down.This will cause the aluminum to conform to the angle of the notch in the V-block.Remove the piece and wipe the bend line off.Depending on the thickness of your piece, you may need to use both hands to bend it.You can use your angle finder to confirm the accuracy of your work.
Step 13: You should draw a bend line across the piece you want to bend.
Run the tip of a dark felt-tipped marker along your planned bend point using a ruler, straight edge or long object as a guide.It is easy to set up a bend if your bend line is long enough to stretch from one edge to the other.If you make a mistake, wipe the marker off with rubbing alcohol and start over.The bend line needs to be straight in order for it to turn out the same way.
Step 14: Put your piece on the edge of the workbench.
Any decent-sized table or desk will do, provided it is sturdy and large enough to hold your piece.The section you will be bending should be positioned so that it extends out over the edge.When selecting a suitable work surface, keep in mind that the metal could cause wear or more severe damage to wood and other soft materials.
Step 15: Just behind your bend line, place a length of scrap wood.
There is a small amount of visible space between the bend line and the metal on the far side if you square up the wood.The bend line should be perfectly aligned with the edge of the wood.An ordinary 2x4 will be perfect for most jobs, but you could also use other types of lumber.The most important thing is that it has enough weight to anchor the sheet.
Step 16: Attach the wood to the piece with C-clamps.
The anvil should be braced against the underside of your work surface if you want the shoe to rest on the top of the wood.To tighten the screw handles, twist them clockwise.Make sure the clamps are stable before you start.The end of the screw is where the shoe and anvil are located.
Step 17: By hand, bend the edge of the piece around the wood.
You can fold the metal around the edge of the wood manually.The amount of force will depend on the shape and thickness of your piece, but most ordinary sheets and plates should be able to give it.Remove the scrap wood when you are happy with the angle of the bend.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.To create a sharper bend, tap the crease where the metal curves lightly with a rubber mallet.Manual bending is best for forming 90-degree angles, but you may be able to produce other angles with steady pressure and a careful hand.