Project #5 from Spike : Very low-budget radius brake
So, i found myself in want today for a radius brake to make my seat pans. I had a slightly more sophisticated setup (but only slightly) that i used to use for this, but when i moved shops last time it did not make the move. Now i need a new one, and i have these modular tool stands that i made to hold all my tools, so i figured i would make an addition that i could drop into place when i need it, and then disappear when i don't.
Starting with the tool-stand...
http://i1168.photobucket.com/albums/...1-24182303.jpg
I then cut some 1.5" x .120" wall steel tube (it drops right inside of the thick wall square tubing that i used for the tool holder) to make a new tool fixture for my 'radius-brake'.
http://i1168.photobucket.com/albums/...24182341_m.jpg
After cleaning up the square tubing, i welded it to a piece of 12x20" steel plate scrap that i had laying around the shop. I tig weld this part so it's nice and clean, and i don't have to worry about weld build-up getting in the way when the post slides into the tool holder.
http://i1168.photobucket.com/albums/...093355_600.jpg
After it cools, then i slide the base for my radius bender into the tool stand and measure and cut a piece of 1.25" x .120" wall steel DOM tubing. It ends up being 20" long to match the long edge of the steel plate i'm using for the base.
http://i1168.photobucket.com/albums/...14162306_m.jpg
I used a flat bar to level the top of the tubing to the surface of the plate and welded it in place with the mig welder (speed and ease was more important than pretty for this part of the project, so i used the MiG welder rather than TiG). For this project, it IS important that the top edge of the tube be level with the top surface of the plate, otherwise your radius bends will be crooked, or will warp the sheetmetal as you bend it.
http://i1168.photobucket.com/albums/...14164227_m.jpg
Now, i have a 1/2" x 2" rectangular bar of steel that i use for this sort of work. position your sheetmetal that you want bent so that the bend lines up with the centerline of the pipe that you welded on, and clamp that steel bar down on top of it, securing the bar and workpiece firmly to the plate/pipe assembly. I use a C-clamp on one side, and a quick release ratchet on the other, so that i can quickly un-clamp the ratchet, reposition, and re-clamp for the next bend.
http://i1168.photobucket.com/albums/...14164602_m.jpg
Now you just grab the edge of your workpiece that is sticking out and smoothly and evenly push it down to make a nice gentle radius bend in the sheetmetal.
