Give me a brake

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I've needed a sheet metal brake for a long time.I've got a job in the shop right now that will be so much easier with a brake.So I spent about 12 hours and used a bunch of drops that have been laying around the shop, and made one that bolts to my layout table.Capacity:Width of bend: 4'-11 3/4"Sheet thickness: 16ga. Degree of bend: Max 96 degrees(The whole time I was building this Van Halen's "Unchained" has been playing in my head......"Hey take a look at this, hey man that suit is you! You'll get some leg tonight for sure! Tell us how you do!""C'mon Dave give me a break.""One break comin' up!"... Chained, aint nothin stays the same, unchained, yeah yeah hit the ground runnin'...") Here's the first test piece. 16g sheet, about 18" wide. The corner radius isn't as tight as I'd like but it'll do just fine for now. One day I'll bevel the edge of some beefy flat bar and re-do the clamp bar to remedy that.Brian LeonardAppalachian Ironworks L.L.C.434 Long Branch Rd, Marshall, NC 28753828 649 9966828 702 [email protected]
Reply:Nice!Wish ya had more photos....  I was just thinking how 'nice it would be' to have something I could put together to bend some simple 90's on some 36" x 24ga. sheet metal for a small project!Cheers,Miller Diversion 165120 amp Buzz BoxVictor Oxy/Ace Oxy/LPGSmith "Little" Oxy/LPGHypertherm Powermax 30Lot's of Misc. tools n' crap....
Reply:12 hours of labor x $50/hr labor rate = $600 press.Making it yourself out of 'scraps' = priceless.  The radius on the test bend looks pretty nice and uniform.Any deflection on the brake during use that you saw so far?  Or is it beefy enough?  The best laid schemes ... Gang oft agley ...
Reply:Originally Posted by MoonRise12 hours of labor x $50/hr labor rate = $600 press.Making it yourself out of 'scraps' = priceless.  The radius on the test bend looks pretty nice and uniform.Any deflection on the brake during use that you saw so far?  Or is it beefy enough?
Reply:Originally Posted by app-ironworksllcI've needed a sheet metal brake for a long time.I've got a job in the shop right now that will be so much easier with a brake.So I spent about 12 hours and used a bunch of drops that have been laying around the shop, and made one that bolts to my layout table.Capacity:Width of bend: 4'-11 3/4"Sheet thickness: 16ga. Degree of bend: Max 96 degrees(The whole time I was building this Van Halen's "Unchained" has been playing in my head......"Hey take a look at this, hey man that suit is you! You'll get some leg tonight for sure! Tell us how you do!""C'mon Dave give me a break.""One break comin' up!"... Chained, aint nothin stays the same, unchained, yeah yeah hit the ground runnin'...") Here's the first test piece. 16g sheet, about 18" wide. The corner radius isn't as tight as I'd like but it'll do just fine for now. One day I'll bevel the edge of some beefy flat bar and re-do the clamp bar to remedy that.
Reply:Well it did so-so with the 4'- 8" long bend in 16 ga. But there was some deflection that caused about 5 degrees difference from the middle to each end.So I added some bracing to the clamp frame (3" x 5lb channel) that stops the clamp bar (2-1/2" x 2-1/2" x 1/4" angle) from bending away from the corner.Then I added some more triangulation to the clamp frame to stiffen it.The results were quite satisfactory with only 1 degree difference in the bend, from end to end, on the same 4'-8" 16 g sheet.I even made an extender for the handles to increase leverage and decrease effort when bending.So it's done for now.Or is it?...to be continued...Brian LeonardAppalachian Ironworks L.L.C.434 Long Branch Rd, Marshall, NC 28753828 649 9966828 702 [email protected]
Reply:Brian,1/4 inch angle iron, eh?  Yeah, a section that is only 1/4 inch material spanning ~5 ft is not too beefy.I think it was on the Miller Projects page or maybe an old article from somewhere else (Metalmeet, old 1950's era Pop Sci, ?? ) that showed a way to help beef up angle iron for use in a bending brake.Take a slightly smaller dimension piece of angle iron and weld it reversed into the bigger piece of angle iron, turning the section into a boxed section instead of an open angle.  Pretty easy and pretty fast way to beef up the angle iron parts.Usually faster and easier than cutting and fitting a whole bunch of gussets.  Although extra gussets could then be fit around the now boxed section for some more stiffening. Attached Images  The best laid schemes ... Gang oft agley ...
Reply:Originally Posted by app-ironworksllcYeah, but I only pay myself minimum wage so 12 x 5.75 = $69.00 labor before taxes.And if I'm in a bad mood come Friday I may not pay myself for building this at all. Think about all the money I'm saving myself.(And I get at least $60 an hour so it'd be $720.00)(plus materials, @ $.60/lb about $120.00)(plus tax)(Dang, that's crazy I should have just bought one)So far no deflection, but it's about to undergo its stress test. I have to make 4 z shaped pieces 3' long and 4 pieces 4'-8" long, from some 16 ga sheet. I'm thinking it may need a gusset on the back of the risers going down to the table. We'll see shortly, well I will. And I'll share my results unless they're too embarrassing.(like the price)
Reply:Great job on the 12 hour bender Really surprised on the Rad. of the bend Don't get me wrong I like the large Rad. just surprised Thank you for posting                                                          Vernon
Reply:Originally Posted by RojodiabloYou might find yourself having a beer on the job. You'd have to dock your pay for the day, and give yourself a suspension day on Friday to boot.  Gotta be careful working for yourself!!!!
Reply:Originally Posted by 1969 VernonGreat job on the 12 hour bender Really surprised on the Rad. of the bend Don't get me wrong I like the large Rad. just surprised Thank you for posting                                                          Vernon