bending thicker aluminum

[SarcasticDwarf]

I am thinking of making a new case out of a sheet of .065 thickness aluminum. The plate is molded and looks exactly like the types used for truck tool boxes.

Once I figure out what blade to cut with, how should I go about bending it? As this is a thicker aluminum, what can I use to bend it? I don't want to damage the exterrior side. The bends will be 90 degrees (obviously). An exagerated and totally not to scale representation can be seen here.

 

[rgwalt]

Well, a sheet metal bender would be ideal... but I would suggest a sturdy table with a straight, sharp edge, some sturdy rubber-soled clamps, and a rubber mallet. You do the math...

Ryan

 

[Ronstang]

Do some tests on scrap pieces because thicker aluminum tends to crack and tear when bent.

 

[isekii]

Originally posted by: Ronstang
Do some tests on scrap pieces because thicker aluminum tends to crack and tear when bent.

yea i don't htink aluminum is that malleable unless you put some serious heat to it.

 

[SarcasticDwarf]

Originally posted by: Ronstang
Do some tests on scrap pieces because thicker aluminum tends to crack and tear when bent.

hmm, will have to watch for that. Is the problem more prevelent in longer bends?

 

[Ronstang]

Originally posted by: DeathByAnts

Originally posted by: Ronstang
Do some tests on scrap pieces because thicker aluminum tends to crack and tear when bent.

hmm, will have to watch for that. Is the problem more prevelent in longer bends?

Yes....the closer you approach a 90 degree bend the more severe the problem becomes but it really depends upon which alloy of Aluminum you are using also. Testing is the best way to find out.