Bending Sheet Metal

[ItchyD]

I'm working on a replacement sheet metal cp (in my brain) and I'm wondering how I can:
a) get the piece nicely to size
b) get nice curves and angles in the bends

I have tin snips, and even power tin snips but in my memory I always get a ragged crappy edge with those tools.

To get the curves do you hammer them or just gently bend them or what?  What's the difference between a nice smooth curve and a sharp change to 45 degrees? 

Should I bend the new blank CP over the old cp?  Is it just going to crush it or what?

Thanks!

[rrcade]

You speak of what I do for a living, You need to go to a local Heating and Air conditioning shop (HVAC) with a drawing of what you want. Have width, length, angles of bends or make a template on cardboard if you can't figure out the angles. They will cut your piece in a Shear and bend it up in a Brake. I can't see them charging you more than 50.00 if that, they probably have scrap that they're gonna throw out bigger than what you need. If you're lucky maybe they'll just do it for free. You're probably gonna want at least 18 gauge metal-galvanized will probably be cheapest. Good Luck

[TheShanMan]

Good timing for the question and thanks for the answer - I need to find a place to bend some sheet metal that is too big/thick for my wimpy 24" brake and really wasn't sure where to go.

[jeffremiller]

Great timing!!!

I recently bought a mameroom CP but I just can't accept the thought of pinball buttons at a 40 degree angle.

Does it sound reasonable to bend a piece of sheetmetal at a 90 degree angle and then bend lips at the ends at 40 degrees to make the buttons perpendicular to the front of the CP?

The problem I am having is finding 3-4 inch wide stock to work with, and the bending of course.

[Crowquill]

Do what rrcade says.

Don't do what I did. It turned out OK, but definitely not what my brake was made for. This project now houses a hacked Xbox 360 controller. Pac-Man CE plays much better with a Happ Super than Microsoft's crummy d-pad.

[rrcade]

Great timing!!!

I recently bought a mameroom CP but I just can't accept the thought of pinball buttons at a 40 degree angle.

Does it sound reasonable to bend a piece of sheetmetal at a 90 degree angle and then bend lips at the ends at 40 degrees to make the buttons perpendicular to the front of the CP?

The problem I am having is finding 3-4 inch wide stock to work with, and the bending of course.

If I'm understanding you correct you can't bend something like that in one piece, it would half to be made in 3 pieces and then welded together, but any HVAC shop can handle it.

[jeffremiller]

Hate to hijack the thread, but here is what I was thinking.

Does this have to be multiple pieces?

[garnerb350]

rrcade is TOTALLY right!. I worked in heating and AC when I was in high school.  They do that all the time (bending  and making lips) to form trunks for air systems. Me and the owner's son use to take scraps and make replacement nerfs bullets with the scrap metal......nobody wouldnt play with us though....

[whammoed]

Would a HVAC place be able to do a bend with a radius?  I believe you need the correct die for the brake to do that and I can't think of a reason for the HVAC guys to have such a die...

[rrcade]

Jeff, if your picture is a side(profile)view Yes that can be made in one piece.

As for the radius question Yes they can do that also, by either having a radius die for a press brake or using a Roller. Any HVAC shop should have all the equipment especially a Commercial shop rather than one that only does residential. You can make anything you can dream up out of metal with the right tools.

[Kevin Mullins]

Jeff, if your picture is a side(profile)view Yes that can be made in one piece.

I agree, that's just three simple/basic bends on a brake.

You can make anything you can dream up out of metal with the right tools.

Indeed ... boy do I miss having a shop available.

(prior military - aviation structural mechanic and aviation machinist/welder)