Sheet metal brake

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I'm wanting to build a brake out of some angle I have laying arround, nothing to outrageous. I just need to be able to bend a 1 inch flange in some 20ga aluminum that's about 12 inches long. So I'm wondering if anyone has a pic of a simple design, I could bend it by clamping it and folding it over but figured why not build a brake. My idea is to lay the meterial on the workbench, clamp a piece of angle over it and then rotate another piece of angle to make the bend, would that work? Or do I need something more heavy duty?Offering CNC Plasma cutting and welding projects.Follow me on facebook https://www.facebook.com/nobigdeal.fabSupport those that support WW.
Reply:Here is a link to the one i built a few months ago. http://weldingweb.com/vbb/showthread.php?t=102981It works great on 16 gaugeDave ReberWadsworth Ohio
Reply:Another one, simpler I think.http://weldingweb.com/vbb/showthread.php?t=57017__David Hillman
Reply:Thanks for the replys, that's a little more in depth than I wanna go this afternoon. I'm just going to swing by harbor freight and buy an 18 in brake. They want less than $40 for one and I can get my project done today. But I will use your ideas to build one in a few months. Planning on a 48 in build. As I really need one and can't see a point in buying one.Offering CNC Plasma cutting and welding projects.Follow me on facebook https://www.facebook.com/nobigdeal.fabSupport those that support WW.
Reply:all you could ever want to know about making them, Monica did a great job on hers ....mine is on page 4http://weldingweb.com/vbb/showthread.php?t=60659bobs77vet/37ford4drEastwood digital TIG200HH190Lincoln Invertec 155sLincoln weldpak 100sears/craftsman (lincoln) 50a 240v buzz boxO/A rig Harris gaugesnexion cut 50 dxchicago electric (HF) 240v spot welder
Reply:Originally Posted by 37ford4drall you could ever want to know about making them, Monica did a great job on hers ....mine is on page 4http://weldingweb.com/vbb/showthread.php?t=60659
Reply:A chunk of cold rolled would give a nice sharp corner to bend aginst. Should help making for a tight radius corner. Might have to look into that.......Again thanks for the links, you guys rock.Offering CNC Plasma cutting and welding projects.Follow me on facebook https://www.facebook.com/nobigdeal.fabSupport those that support WW.
Reply:Sorry dudes, here's a better write up:My project for a project.  I'm building a 10' workbench in the garage.  I wanted a built in tool cabinet in the bench which means drawers.  I wanted metal drawers not wooden drawers.  So, it was do a lot of cutting and welding, or bend some sheet, which still involved a lot of cutting an welding (haha joke's on me)Let's built it...(fast forward)...ok, done Press Brake (in finger brake mode)7 of 10 drawers mountedThis press brake bends up 16ga sheet metal and it is workbench mounted.  (can be converted to it's own stand).  Widest piece so far is a 30" bend.  Pretty good for a home built unit.Major materials:(3) 4' long 3x3x1/4" angle iron(2) 5/8" bolts (grade 5 what I had)(1) 10" black pipe(2 sets) nut, washers, 1/2"x3" bolts (grade 8) (2) 1' 1/2"-13 threaded rod & buncha nuts(2) 4'x3"x3/16" steel flat strapWood blocks (length and size varies with your project)Set up two pieces of angle on the workbench.  This sets the max for material thickness.  In this case 1/16" for 16gaDrill your bolt holes.  I used 3"x1/2" Grade 8.  Should look like thisMade my hinge pins from the 5/8" bolt. Cut 10" black pipe to three pieces for each bolt.Grind weld seam with dremel. The hinge has to be centered between the base piece and the bender piece.Measure and cut notches in all three pieces of angle.  The base and bender need to fit the hinge - remember, centered axis!.  The top piece needs to be clearanced or the hinge in so it sits flat.  Weld the hinge on.  This is a critical step.  Pins must be straight and centered on the folding axis.Continued below... (please hold questions until I get the entire thing posted, for continuity)Lincoln AC225 and CartLincoln WeldPak HD and CartOne hand
Reply:You ought to end up with something like this on both ends.  Should have 90* at all points of the width if you did it rightGet your black pipe handle mocked up and welded on the bender piece (sorry very little in progress pics and didn't even go the full mock up with diagonals).  I used 16" wide and 24" worth of leverage, mitered 45*s for the corners.  Once the handle is welded on take one of the 3"x3/16" steel straps and notch it, then stitch weld it in at a 45* in order to triangulate the angle.  Take the top plate and also install it's 3" strap.  Careful here, before you attach it you must cut to length to match the width inside the hinges. Remember, you need to have room to access your bolts.At this point, you're ready to bend up some metal with the basic brake.  This means you can bend sides 1 and 2.  In order to bend sides 3 and 4 you'll need to continue with the finger brake mods.Continued below...Lincoln AC225 and CartLincoln WeldPak HD and CartOne hand
Reply:So now you have sides 1 and 2 done.  Your stuff looks like this.Bends 3 and 4 are going to be tricky as now you can't snug down the top plate to secure your material.  What you have to do is create a spacer block that fits the width of the inside of your box and is taller than the sides.  This spacer block will be sandwiched by the top plate to hold down your material.  You're now building finger brake capability.  I used 4x6 pressure treated lumber scrap as it is what I had.  I cut it to inside width of my drawers and I was in business.Notice the threaded rod and nut setup.  Instead of the long threaded rod you can use big C-clamps, but the rod works for me.  You must secure the bose plate to the workbench, hence the extra nuts.  You can stick with a lock washer, I show a jam nut because I was out of 1/2" lock washers.  Just ensure the setup is secure.  Also notice the nut under the top plate.  This is use to suspend the top plate when you remove the block and material to reposition or insert the next one.  Otherwise you'll smash your hand the first time (ask me how I know).Another trick is to use a back stop to support the material.  Keeps it from sliding back.  Remember your top plate setup isn't as secure and there's more leverage as the plate is higher up.  It makes the material tougher to bend and hold down.One more tip, and it's a good one, smooth up the bender face.  It reduces the friction of the bender face as it slides up the material when it bends.  Makes it easier.  Also I forgot to mention it earlier, but grease your hinge pins.Anyway, there's your boxHave fun welding the corners [coffee]  I'll be doing a few things to modify this brake for efficiency but as it is, it'll get the job done.Lincoln AC225 and CartLincoln WeldPak HD and CartOne hand
Reply:GREAT JOB MONICA!!!!! Very impressed. Is the cabinet and drawers for shoes and clothes! I'm only kiddin with ya, i'm an idiot, couldn't resist  Serious tho, real nice work I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Originally Posted by weldermikeGREAT JOB MONICA!!!!! Very impressed. Is the cabinet and drawers for shoes and clothes! I'm only kiddin with ya, i'm an idiot, couldn't resist  Serious tho, real nice work
Reply:I was gonna go there, but didn't wanna get flamed!!!!!! LOL, you do great work, CHEERSI hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Originally Posted by weldermikeI was gonna go there, but didn't wanna get flamed!!!!!! LOL, you do great work, CHEERS
Reply:Nice. I plan on building one myselfHypertherm Powermax45Miller auto 140 migMiller Econotig Watercooledwith wp24w TorchLincoln Power255XTNew(Lincoln V205 ac/dc)Miller Elite Helmet
Reply:I didn't make this one, but if I were going to make one, I would pattern it after this, it's a Malco brand. I bought it about 8 years ago. It has served me well. I use it to make sheet metal transitions in the field when I change out central heating & ac systems.Mastering others is strength, mastering yourself is true power.
Reply:Here's a pic of it. Attached ImagesMastering others is strength, mastering yourself is true power.