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Bending sheetmetal

Brno8x57

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Oct 20, 2017
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Maryland
I’ve been making some small pieces of 18-20 gauge sheet metal to repair a rusted out car I am restoring. I’ve been working with small pieces that I was bending by hand. Doesn’t look that great.
I would like to get a brake but don’t know what to look for.
What kind of brake is recommended?
Pieces will be about 30 inches max.
 
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p_mori7

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Montreal, QC., Canada
A good length of hardwood, a couple of large C-clamps, and a couple of sheet metal seam pliers have gotten me out of a jam several times.

Use a pencil to mark the bend lines, place the sheet metal on your work bench with the first bend mark hanging over the edge, clamp the piece of hardwood over the sheetmetal and to the bench. Use the pair of seam pliers to grab the sheet metal and bend.

This reminds me that I need to fix the RH rocker panel on my daughters '05 Cobalt this spring.
 

DIY_Guy79

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Tulsa, Ok
Depending on the size, the best way to do it by hand, would be to make a jig and use a hammer or mallet. If its small enough you can clamp it in your bench vise at your bend line, make sure its square, and hammer it down til its bent to the desired angle.

For larger pieces, You could go get a couple lengths of 2x2 angle iron, and clamp them to the edge of your work bench or another sturdy place and bend them like that. Take one piece of angle and put it on the edge of the work bench, like a long corner cap, Then take the other piece and face it the opposite direction, with your sheet metal between them, calmp it securely with good clamps & whomp accordingly lol. You could prob also use wood instead of angle iron, but the angle iron would make for a more concise and effective make shift break. Also, if you're needing a rounded bend, use pipe instead of angle iron on the bottom side of the bend and hammer the metal to the shape of the pipe.

The key to getting good clean bends is first off making sure you're measuring where the bend needs to be, and then making sure you have it nice and square with your break jig. And then making sure you have a good solid jig to hammer on and form your sheet to. If you have something flimsy, your metal is going to be allowed to bend passed where needs to stop depending on how hard you hit it which will likely result in an inconsistent bend. Alternatively, instead of using clamps, to make the jig much easier to deal with and much more solid, Drill some holes and put some long bolts in them, that way instead of fumbling with clamps, you can just loosen/tighten a couple of bolts. The just make sure you have them flush/square with each other and drill them at the same time so you dont risk being off on your hour drilling a bit. I would personally weld them at the ends, drill them, then cut the welds with a grinder.

And if you really want to get fancy, you could make an actual hand break very easily if you can weld. Just weld some hinge taps on each end of the angle, secure them with lock nuts & bolts. Wed you leaver on to the pivot piece, drill some screw holes in to the other to secure it to your work bench or whatever work surface, and bam, stick you some metal in, pull the lever and bend the metal. You'll probably save money and end up with something better and suited for your tastes than whatever chinesium you can find to buy. this way.

More than one way to skin a cat. Just gotta put your mind to it.
 
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Brno8x57

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Oct 20, 2017
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Maryland
I’ve done the manual bending using hardwood templates and a straight edge but would like to get a machine that can make cleaner bends.
For car frame and body repair, do I need a finger brake, bar bender, or plain brake?

Will the 3 in 1 units be of any value?
I’ve been looking on Craigslist and FB but so far the brakes are just too big.
Anything over 4 feet is going to be hard to transport and no room in my garage.
 

macgee

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Sepulveda Pass, CA
I guess better to first ask, what is you budget? How often will you be using it and what kind of space do you have to fit one?

Agree with isb,

Pexto (Peck, Stow, & Wilcox) make really nice old school brakes that can be found when patient. Back in the day, they were in almost every high school and college shop. Tooling and wear for all of these is key to check on. Less frustration and better results when working well
The HF versions can be a nightmare and also could be useful, depending on jobs and the day it was made (recommend avoiding the ones made Monday morning and Friday late afternoons)

A lot will depend on budget and space.
 
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Brno8x57

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Oct 20, 2017
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Maryland
I guess better to first ask, what is you budget? How often will you be using it and what kind of space do you have to fit one?

Agree with isb,

Pexto (Peck, Stow, & Wilcox) make really nice old school brakes that can be found when patient. Back in the day, they were in almost every high school and college shop. Tooling and wear for all of these is key to check on. Less frustration and better results when working well
The HF versions can be a nightmare and also could be useful, depending on jobs and the day it was made (recommend avoiding the ones made Monday morning and Friday late afternoons)

A lot will depend on budget and space.

I have room for the HF 36 unit or similar size. Budget about $700.
Do these have different names or should I just search for sheetmetal brake
 

NUTTSGT

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Northern Central Ohio
I bought one of the HF 3-in-1 brake/shear/roller. It went back the day I bought it when it couldn't shear less than what it was rated for.

I bought a brake at TSC, probably the same thing HF carries, just badged different from TSC. It doesn't do bad.
 

isb cornbinder

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Nov 3, 2010
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Location
Pacific South West, BC, Canada
I bought one of the HF 3-in-1 brake/shear/roller. It went back the day I bought it when it couldn't shear less than what it was rated for.

I bought a brake at TSC, probably the same thing HF carries, just badged different from TSC. It doesn't do bad.

I would not have a three in one if it was offered to me for free. My space is a little tight and if I can squeeze in another machine, I has to be something really good, preferably "old school". Brown Boggs is another fantastic machine.
Someone put the false word out that I can repair these 3 in 1 units. I will not ever try.
 
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mikegt4

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sw ohio
Ok then the 48" 16ga box & pan is the ticket. When I go here it wants to give me a 5% code, so might keep you right around your $700 budget
https://www.grizzly.com/products/grizzly-48-pan-box-brake/g5769

I have one of those. It works pretty well but as with most Chicom tools it is a bit crude compared to classic American iron (which I was used to). A pan brake is going to be a lot more versatile for small parts found in car bodies, especially the supporting structure.

After looking for used brakes on CL for months I finally bit the bullet during the height of the pandemic when Grizzly offered free shipping, saved $150.
 

HMCFab9

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Fox valley area, Wisconsin
An old Pexto is probably the best option IF you can find one.
I looked for years & finally settled on a J.E.T. 48" 16 gauge box & pan brake.
Baileigh Industrial, Tennsmith & Grizzly are other options.

If you plan to use it for more than 1 project & want nice crisp / accurate bends don't buy a cheap one.
 
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Brno8x57

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Maryland
I have one of those. It works pretty well but as with most Chicom tools it is a bit crude compared to classic American iron (which I was used to). A pan brake is going to be a lot more versatile for small parts found in car bodies, especially the supporting structure.

After looking for used brakes on CL for months I finally bit the bullet during the height of the pandemic when Grizzly offered free shipping, saved $150.

The pan/brake combinations look pretty nice.
24inch looks manageable but limited. 48 looks like a beast but much more useful.
 
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Brno8x57

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Joined
Oct 20, 2017
Messages
88
Location
Maryland
An old Pexto is probably the best option IF you can find one.
I looked for years & finally settled on a J.E.T. 48" 16 gauge box & pan brake.
Baileigh Industrial, Tennsmith & Grizzly are other options.

If you plan to use it for more than 1 project & want nice crisp / accurate bends don't buy a cheap one.

I’ve been looking but without knowing what to look for, I’ve been hesitant when one is found. Can’t tell if they’re complete, damaged, or even useable.
 

NUTTSGT

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Location
Northern Central Ohio
I would not have a three in one if it was offered to me for free. My space is a little tight and if I can squeeze in another machine, I has to be something really good, preferably "old school". Brown Boggs is another fantastic machine.
Someone put the false word out that I can repair these 3 in 1 units. I will not ever try.

I learned my lesson that day. After spending an hour and a half cleaning the cosmoline off of it and then trying to shear a piece of smaller gauge sheet metal, I was not happy. Rather, I was so pissed I picked the damn thing up off the work bench and put it in the bed of my truck to take it back.
 

lis2323

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Joined
Dec 25, 2016
Messages
3,234
I have a Brown Boggs finger brake


556d883dae1fd0c90b6c9f5c33d29232.jpg


but for automotive work an electromagnetic brake would be most versatile.

b6e401ec94ad510e556d1812c8244a7c.jpg


Sent from my iPad using Tapatalk
 

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isb cornbinder

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My Dad was very clever and a true draftsman. I asked him to watch for a brake, for me. He made this one in two days.
I have sold the Dad Made Brake to a much appreciative small shop guy. I know Dad would approve, 100%
Sadly, Dad left this world in 1989. He would have been 103, this year.
 

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Mallen

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Aug 11, 2021
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649
I guess better to first ask, what is you budget? How often will you be using it and what kind of space do you have to fit one?

Agree with isb,

Pexto (Peck, Stow, & Wilcox) make really nice old school brakes that can be found when patient. Back in the day, they were in almost every high school and college shop. Tooling and wear for all of these is key to check on. Less frustration and better results when working well
The HF versions can be a nightmare and also could be useful, depending on jobs and the day it was made (recommend avoiding the ones made Monday morning and Friday late afternoons)

A lot will depend on budget and space.
That's just a myth based on American ideas of a work week. Its not like the poor SOBs get weekends off. They can be junk any day of the week.

I was going to laugh at this, then I realized, that's really how it is.
 
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