Bending Sheet Aluminum. Got any advice?

[CanaBalistic]

Im having a hard time trying to figure out the best way to wrap a case in side a sheet of aluminum. The look im trying to go for is the same basic shape as an Apple G5. Have you got any ideas as to how i can bend it?


Here is a basic sketch with as many measurements as i could think of.

[DaveW]

When i bend metal, i hit it with a rubber mallet. I screw it into a vice and belt it.

My advice is full of flaws but i figure hey, it's better than nothing. The rubber mallet works good for flatenning your mistakes out too

-Dave

[Cevinzol]

a bending brake is best. you can get a cheap one for about $25 US from harbor freight. However I have seen people just clamp the sheet between 2 pieces of angle iron on the edge of a bench and bend it over with a board. Check the link to see how one looks. The mallet idea will work but you have to beand the whole length together, a little at a time otherwise you can cause the meatal to stretch.

also the type of aluminum you use can affect how you do it. Street signs are made out of T6 alloy and it is incredibly stiff and hard to bend. So just an FYI.

[CanaBalistic]

No its not going to be out of street signs...

I have a 3' x 6' sheet of 3/16 thick "regular aluminum" . It should be just enough for what i need.
I just got access to a brake press. I hope the sheet fits as its not a big press. I have got to make sure all my measurements are correct before i even scratch it.

[tybrenis]

No its not going to be out of street signs...

I have a 3' x 6' sheet of 3/16 thick "regular aluminum" . It should be just enough for what i need.
I just got access to a brake press. I hope the sheet fits as its not a big press. I have got to make sure all my measurements are correct before i even scratch it.
Check Cheap as chips Catalogue and Early Settler Catalogue.

3/16" Woah, thats some heavy stuff for a computer.

You could try bending it with the angle iron/clamping method, but your easiest, cleanest bet would be on a brake. At $25 you can't go wrong with the harbor freight brake. I'd say the price is right on that one.

[CanaBalistic]

I dont think that brake will work. I need somthing to make rounded corners, not just 90* angles. Its a shame because that would be the perfect size for the sheet.

[Cevinzol]

well as a last resort. take it to a metal fabrication place and have them do it. call around and see how much it would cost.

[CanaBalistic]

Well the guy who is letting me use his brake is a metal fabricator. The major problem is that he cant help me at all with it as we have diffrent work scheduals. He said i could have free reign over his tool shed while he was st work.

[b4i7]

in my machining class we built a sheet metal bender.....ill try to get a hold of my teacher...see if he cant send me the blueprints and such for it...its pretty nice....specially if you got the tools to make it

[CanaBalistic]

That would be nice. I'd have access to just about everything. Not that i'd know how to use it all.

Right now im sorting out the rest of the chassi and parts for this build. Someone inverted thier case to make it appear BTX. Its an intresting idea that im thinking about. Somthing extra special for this beast of a machine.

I need a name for it before i can stick it in the work log thread.