Bending 5052 .080" aluminum sheet with a bending brake?

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Okay so after aquiring a lot of my first weling equipent im in the process of wanting to start building my first project/s . I want to build panniers for my adventure motorcycle (basically boxes/side saddle storage) out of aluminum sheet. Ive decided i want to use 5052 .080" aluminum sheet for these. My goal is to bend most of what i can and tig weld the rest together. My idea was to get one of these: http://www.northerntool.com/shop/too...duct_7825_7825And be able to bend the body and the lid to the box with it.  The bending brake says the max thickness is 16ga. .080 is more like 12ga right? Will i have a problem doing this?How do bend radius's work with these manual bending brakes?? This project could possibly turn into a side business for me making more of them so i want to build these panniers to the best quality possible. I really appreciate any help. This forum has helped me out so much since getting into welding.Dynasty 200DX   (2014)Millermatic 211 (2015)Optrel 864   (2014)Smith Medium duty MBA 30510 (Xmas 2014)Tennsmith 16ga 4ft finger brake (2015)Trailblazer 325 EFI and excel Thermal dynamics Cutmaster 82Miller maxtron 450
Reply:If you don't anneal the aluminum you will just break it at the bend..It will crack and make life miserable....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Really?! Damn. Theses a company that produces these things commercially and they bend them like im talking about. Are they really annealing them before each and every bend? Or is there another, quicker way. They are also using the same thickness aluminum sheet.Dynasty 200DX   (2014)Millermatic 211 (2015)Optrel 864   (2014)Smith Medium duty MBA 30510 (Xmas 2014)Tennsmith 16ga 4ft finger brake (2015)Trailblazer 325 EFI and excel Thermal dynamics Cutmaster 82Miller maxtron 450
Reply:Zapster, what about increasing the bend radius. Not sure how i would with such manual bending brake that i linked but theres got to be a way. 5052 is supposed to bend pretty well.Dynasty 200DX   (2014)Millermatic 211 (2015)Optrel 864   (2014)Smith Medium duty MBA 30510 (Xmas 2014)Tennsmith 16ga 4ft finger brake (2015)Trailblazer 325 EFI and excel Thermal dynamics Cutmaster 82Miller maxtron 450
Reply:outdoort,According to this link 5052 in an H32 temper designation has good cold formability.   http://www.wilsonsmetals.com/datashe...2-H32_138.asmx
Reply:Try a small piece and see what happens..You don't need a brake for this you can use a vice and hammer/pliers.....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:outdoort,From what I read at that link you gave to that Northern Tool brake it's not capable of bending .08" material.  It says max thickness capacity of .03".   It also says 1.5mm aluminum but that's only .06" (approx).
Reply:Originally Posted by zapsterIf you don't anneal the aluminum you will just break it at the bend..It will crack and make life miserable....zap!
Reply:.080 aluminum is roughly 14 gauge. A 16 gauge brake should  have no problem. 3003 aluminum would be easier to bend but 5052 should work. These alloys are typically annealed already. You shouldn't need a big bend radius on soft aluminum. Set your top leaf back about 3-16" and you should be good.
Reply:I don't think that northern brake will be stiff enough.I think you can technically get away with .080 on a real 16 gauge brake, but that one looks light. If is like the other Northern brake I had, the manual will say it can only bend 8" of 16 gauge, or full length 18 gauge.A real 16 gauge machine should do it, but you'd be much better with a 12 gauge machine.Who is John Galt?
Reply:I just like to test bend aluminum before fuching up all the material if it DON'T work..Better safe than sorry....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Originally Posted by zapsterIf you don't anneal the aluminum you will just break it at the bend..It will crack and make life miserable....zap!
Reply:5052 bends well. http://weldingweb.com/vbb/showthread.php...ade-snow-shoes
Reply:I beat the crap out of my cheap pos $250 HF sheet metal brake. I think it is rated to like 18g steel and some thin aluminum foil. I bend .125" aluminum with it, I use big C clamps to hold it together and big cheater bars on the ends to yank on. The whole things twists and deforms and acts weird but it gets the bend done.I really need to upgrade it bad.12v battery, jumper cables, and a 6013.I only have a facebook page. https://www.facebook.com/pages/VPT/244788508917829
Reply:Originally Posted by zapsterIf you don't anneal the aluminum you will just break it at the bend..It will crack and make life miserable....zap!
Reply:Wow thanks for all the responses! Looks like i need to go shopping then lol. So, what are the recomended manual bending brakes (with fingers) if the northern tool one is a little cheap? I really cant spend over 1k and really im just looking for something around 500 dollars. Il look used if there are good older usa made brands out there. Which are they?Dynasty 200DX   (2014)Millermatic 211 (2015)Optrel 864   (2014)Smith Medium duty MBA 30510 (Xmas 2014)Tennsmith 16ga 4ft finger brake (2015)Trailblazer 325 EFI and excel Thermal dynamics Cutmaster 82Miller maxtron 450
Reply:I've got the Baileigh electromagnetic break. You can't beat it in terms of versatility. It can bend boxes no other break can bend. Correct me if I'm wrong, but finger breaks can only make a box that's what, 4" high? And the 200 ton industrial brakes maybe 12"? I bend boxes with 36" walls on this break. And you can use round stock as the die to make radiused bends, you can hem edges, etc. It's expensive, about $2k, but if you plan to do a lot of sheet metal work and boxes, this is the tool to get.John 3:16(2) Miller Pheonix 456(2) Millermertic 252Dynasty 210DXHobart 210MVPDoringer D350 SA Cold SawScotchman 350LT Cold SawWebb 10x50 MillWebb 15x40 LatheGeka Bendicrop Ironworker
Reply:I got a Harbor Freight 36" brake used.I did the mods as outlined in the 4x4 off-road forum, and I can get a decent 90 on 2 ft of 14ga hot rolled, with some radius.16 ga steel 36" wide has a nice tight 90.The radius can be increased by just setting the top piece to clamp down a little farther back than you would for a square corner....but I'd rather have a real brake.When I absolutely need one, I will get one.That will be when it is costing me more money not having one.Hobart Beta-Mig 2511972 Miller AEAD-200LEMiller 250 TwinNorthern Ind. Hybrid 200Longevity Stick 140Longevity Migweld 200SThermal Arc Pak 3XR
Reply:Ya i admit iv never used a brake before, and im not sure how those height ratings are measured. My plan is to bend the bottom and two sides to the box in one sheet, then cut two separate sheets to complete the other two sides to the box. These two sides will be tig welded all around to the bottom and sides of the longer bent sheet. Then the lid will be bent in one piece with the corners welded together.  My understanding is that the heigth issue arises when a box is bent in one sheet with all 4 sides to the bottom being bent? The sides to ur box then gets in the way of the press?Dynasty 200DX   (2014)Millermatic 211 (2015)Optrel 864   (2014)Smith Medium duty MBA 30510 (Xmas 2014)Tennsmith 16ga 4ft finger brake (2015)Trailblazer 325 EFI and excel Thermal dynamics Cutmaster 82Miller maxtron 450
Reply:Originally Posted by EcondronI've got the Baileigh electromagnetic break. You can't beat it in terms of versatility. It can bend boxes no other break can bend. Correct me if I'm wrong, but finger breaks can only make a box that's what, 4" high? And the 200 ton industrial brakes maybe 12"? I bend boxes with 36" walls on this break. And you can use round stock as the die to make radiused bends, you can hem edges, etc. It's expensive, about $2k, but if you plan to do a lot of sheet metal work and boxes, this is the tool to get.
Reply:Originally Posted by outdoortYa i admit iv never used a brake before, and im not sure how those height ratings are measured. My plan is to bend the bottom and two sides to the box in one sheet, then cut two separate sheets to complete the other two sides to the box. These two sides will be tig welded all around to the bottom and sides of the longer bent sheet. Then the lid will be bent in one piece with the corners welded together.  My understanding is that the heigth issue arises when a box is bent in one sheet with all 4 sides to the bottom being bent? The sides to ur box then gets in the way of the press?
Reply:http://www.eaa.ca/experimenter/artic...wto_brakes.aspyou can make your own brake too
Reply:Originally Posted by VPTI have been real interested in these mag brakes for quite some time now. However they have a somewhat low gauge limit and I don't think a mag brake can be cheated like a mechanical brake can? I have very very limited room in my shop so whatever I get has to do it all. Another new thing I wonder about the mag brake is if it can bend diamond plate? I would imagine there would be problems because of the air gap?
Reply:Originally Posted by outdoortSo, what are the recomended manual bending brakes (with fingers) if the northern tool one is a little cheap? I really cant spend over 1k and really im just looking for something around 500 dollars. Il look used if there are good older usa made brands out there. Which are they?
Reply:Okay thanks for the tips everyone. Looks like ive decided to wait a bit to see if a good usa made used one pops up or possibly save my money for the tennsmith 48" table tob finger break sold for around 1400 dollars. The enco one linked above looks to be built pretty light. Anyone else have any experience with those enco finger brakes and some related input to what id like to do with this finger brake??Dynasty 200DX   (2014)Millermatic 211 (2015)Optrel 864   (2014)Smith Medium duty MBA 30510 (Xmas 2014)Tennsmith 16ga 4ft finger brake (2015)Trailblazer 325 EFI and excel Thermal dynamics Cutmaster 82Miller maxtron 450If you are anywhere near the Bay Area in California, I'd be happy to help you bend that.  I work in aluminum and bend that gauge in 50xx series all the time.  I have the Baileigh 5216 SBR, so we could roll a cone to fit around your tailpipes too...Kevin / Machine_Punk from The Aerodrome Studio - Lincoln PowerMIG 210 MP - Meco N Midget w/custom welding station - Vintage Victor 100Current Projects: The Aerodrome Studio
Reply:Originally Posted by Machine_PunkIf you are anywhere near the Bay Area in California, I'd be happy to help you bend that.  I work in aluminum and bend that gauge in 50xx series all the time.  I have the Baileigh 5216 SBR, so we could roll a cone to fit around your tailpipes too...