Bending 1/8" sheet

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I've been given a 3'x3' piece of 1/8 sheet.  I need to build a box 36" long x 6" deep x 6" tall.  Basically a big U if looking from the end before the caps are put on.  I have a welder and grinder, but that is it.  A couple of questions...1) what is the best way to cut strips out of this material?  I don't have a sheer press, etc...  Will a steel cutting disk in a circular saw work?  Don't laugh, that's why I am asking....2) Once the strip is cut out, what would be the best way to bend it into the U shape?Thanks!
Reply:Originally Posted by wicrules1) what is the best way to cut strips out of this material?  I don't have a sheer press, etc...  Will a steel cutting disk in a circular saw work?  Don't laugh, that's why I am asking....
Reply:Thanks for the quick reply.The box is going to be mounted on the back of our camper.  It will store some metal support bars used to hold up the rear slide.  Right now they take up valuable storage space in one of the compartments.I've got some plans for a cheap, light duty metal brake.  It may work for this job if I score the metal.I hadn't thought about scoring the metal.  That makes sense.Wic
Reply:I have used the skilsaw on 1/4 plate and it was SLOW, and I had a hard time keeping a straight line.  What I learned to do was to use my angle grinder with cutoff wheels.  You scribe a good line, then score it with the grinder carefully, then continue scoring deeper and deeper until you cut through.  As for bending, same technique, only don't score all the way through, about 1/2 way should do the trick.  Worked for me anyway.  I would weld the seem where the fold is to reinforce it.Contact me for any metal polishing needs you may have, my avatar is a pic of a standard, painted fire axe that I ground, sanded polished and buffed to a mirror finish.
Reply:If you are going to do some sawing, then why not cut out all the pieces. Don't form a u, just cut panels.TSC and Northern sell metal cutting circular saws for around 120 dollars.  Blade from 25-40 dollars.  Might not be worth it for one project, though quite valuable for cutting sheet with out a shear.  For the width you are trying to brake, perhaps the homebuilt brake plan might do.  However build very stout.  1/8" Is not light material to bend.
Reply:Thanks for the input guys.  I'm hoping with a good straight edge and being patient and careful I can get a decent enough cut.  For the length I need, I don't think I would ever get it cut with an angle grinder....tapwelder, I figured scoring 1/2 way through and bending would be easier than all the cutting and full welding of the seams.  I plan on reinforcing the bend/score periodically with a short bead, however.The brake uses 3x3 1/4" angle with bracing to keep it stiff.  I figure with the 1/8" cut 1/2 way through it would be sufficient to bend it.Thanks!
Reply:Why are you using 1/8"?  Seems a bit heavy for just a box on a camper.  I would use 14g or even 16g - much easier to cut and bend!  cheaper too!
Reply:I believe he already has the steel.DennisThermal Arc 185-TSWMillermatic Challenger 172VictorO/AAtlas Craftsman 12 by 24 LatheEsab PCM-875Wholesalem Tool Mill-Drill
Reply:You will not have a problem using a skill saw and abrasive blade, it is slow but not hard to control.  The use of a straight edge guide is a must! Abrasive blades have a few drawbacks:They where down during use.They are a HOT cutThey can explode if used wrong.Shallow cut are the key! Even 1/8" will cut better with two passes, this is why you need the guide.  If you want to make a small investment in tooling, I recommend;http://www.lenoxtools.com/enUS/Produ...AW_BLADES.htmlMe!
Reply:Thanks for the continuing replies.To answer questions... yes I already have the steel.  It was given to me.  Free is cheap Yes, it is heavy, but its free, I can weld it ok with my mig and maybe someone trying to break into it/steal my support bars will have to work just a little bit harder....There is a local supply/machining shop I have bought some steel from before here in town.  I am thinking about calling and seeing how much they would charge me to cut and bend it for me.  Then I can weld everything up.Thanks!Wic
Reply:location?Me!
Reply:I was just going to suggest shearing and breaking. I used to use one that charged 50 cents per shear and 50 cents per break. I'm sure it has gone up a little since then, and the work we referred to them probably helped some as well. Still they shouldn't charge too much and will save you a lot of work. I have seen guys seriously injured using those abrasive blades.The difference between art and craft is the quality of the workmanship. I am an artist.
Reply:Originally Posted by Jolly Roger I used to use one that charged 50 cents per shear and 50 cents per break. I'm sure it has gone up a little since then...
Reply:I got all the pieces cut out and the box welded up over the weekend.  I went through 1.5 disks just cutting out the pieces.I ended up making a jig out of scrap plywood that supported both sides of the cut.  I have a straight-edge clamp I use woodworking that worked great for getting a straight cut.  It was slow go, but the pieces were straight and consistent.I am going to try and get the lid welded up this weekend and the hinges put on.I am taking pictures as I go, so I will try and get the results up when I get done.Wic
Reply:pictures, we like pictures!Me!