Bending boxes

[brt]

Folks,

I need to make up a few smallish (6" or less) boxes and other similar enclosures out of thin aluminum sheet (1mm, or so). I've done some shearing and bending on largish, single function shears and bending breaks in a makerspace in the past.
But in my own shop, I have neither the space nor the $$$ for a pair of $1,000 machines. So I'm looking at:
- Tiny: http://www.ebay.com/itm/Mini-8-x-18...862?pt=LH_DefaultDomain_0&hash=item43bea91906
- Small: http://www.ebay.com/itm/Sheet-Metal..._Automotive_Tools&hash=item19e1807f58&vxp=mtr

Does anyone have any experience with these or similar machines? 12" wide is about as big as I can find the space for, so that's pretty much the limit for me right now.

Are there other approaches to making boxes and enclosures that's not too labor intensive and can be made to look reasonable with a little TLC?

 

[pjf134]

Ben,
Many different ways to do it.
1.) Go to a place like metal super market and have them make up some for you or sheet metal shop.

2.) Buy material cut to size and bend yourself between 2 pieces of steel and use a body hammer to bend.

3.) Make your own bender ( not hard) and a lot of plans are out there and simple. I once made one that fits in a vice to make rocker panels for cars.

4.) Get to be friends with someone in the HVAC install biz, they make ductwork all the time for furnaces and should be simple for them.

5.) Harbor Freight has tools for the job you need, check them out to compare.

I hope this helps some,
Paul

 

[Tony Wells]

If you have a hydraulic press, or a largish arbor press, you can make some dies that will do bends, but a box brake is a little different and can be shop built at whatever size you need. I've been wanting to build one myself for some time, but still have too many projects ahead of it.

 

[metalman]

I used a paper cutter to cut thin aluminum before I got a real shear.


http://www.harborfreight.com/18-x-15-paper-cutter-60367.html

My first brake was an 18" brake like this:

http://www.harborfreight.com/18-inch-bending-brake-39103.html.

The bends could also be made by clamping a couple pieces of wood or angle along the bending line to aid in folding. Or if the sides are short you can get by with a flange bender like this:

http://www.harborfreight.com/18-inch-sheet-metal-folding-tool-96523.html.

 

[hman]

For boxes of 6" or less, you might want to consider a vise brake. Grizzly sells them for $40 + shipping: http://www.grizzly.com/products/6-Vise-Brake/H3245

The male die comes in several sections, so you can bend between existing sides. I've used one, and had pretty good success with simple bends in thin materials. 1mm aluminum should be no trouble at all.

 

[churchjw]

I have worked on a machine like the second one you posted. Not the same brand but it looked just like it. I can't remember the brand it could have been JET since that is where most of the machines we get for the shop come from but I would not bet money on it. (a mind is a terrible thing to lose) I do remember is was not cheap. IT SUCKED and I only say that because I lack the proper words to convey how bad it really was. I would stay clear of these. At $300 it is a rip off. You would be much better off with any of the other suggestions here.

Jeff

 

[stern]

I have one of the larger HF ones like shown in the second link, and right now its sitting disassembled on a bench because it was a piece of crap. The materials they made if from are sturdy enough, but the concept suck (turning a handle raises the lower brake section). If you only want to do aluminum it MAY work if its thin enough. This thing would barely bend 18 gauge steel, and refused to do anything with 16 gauge.

I took it apart as Im planing on salvaging the break and sheer bits and making two separate units (modules really) that can be used on a hydraulic press. Since I have no real free shop space left I decided to make a 4' wide press, then slot which ever unit I wanted to use in it, while also being able to use it for broaching and pressing.

 

[brt]

Thanks for all the advice, folks. The negative feedback on the $300 machine makes it clear it's not a good option. All things considered, I think I'll go with the vise brake from Grizz (http://www.grizzly.com/products/6-Vise-Brake/H3245) - it looks like the best option from the point of view of trying things out for the least cost possible. If I need something better later, I'll upgrade. But in the mean time - this is a great way to start. Thanks for all the ideas!

 

[metalman]

I have to agree. Most of the 3 in 1 (shear, roll & break) machines are not worth their cost or trouble of trying to get them to work properly. They'll do 1 mm aluminum but they're still not worth it. Even the 18 inch brake in my previous post is a PIA compared to a real brake, but it's only $45. I think I gave $18 for mine back in the day and it paid for itself a hundred times over before I invested in a 4 ft Tennsmith box and pan brake. Then an 8ft 8ga D&K brake and later a 150 ton press brake... but I still have the little one and still use it on small jobs.

 

[Rong]

The advantage of the bigger one is that it has fingers which will be useful if you are making boxes as you would only leave in the fingers needed to match your box width. With the smaller one, boxes might be a challenge. A bender, while not as elegant as these press brakes, might be better as you can clamp the piece to be bent with a piece of scrap metal the width of your box. I think you can get an 18" one at Harbour Freight in the $50 range. And its small enough that you can tuck it away when not needed.