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Test 2 of The Box and Pan Brake – Making Progress

Using Deep C clamps to clamp the clamping board

Using Deep C clamps to clamp the clamping board

In the last post about the brake “The Second Baby-Step with the Box and Pan Brake , the problem I had was the clamping board slipped backward when I bent the metal.  This gave me a very rounded corner.  To fix that problem I purchased a couple of deep C-clamps  I then cut a strip and tested the brake. There is good news and there is some bad news.  It is kind of 2 steps forward and 1 step back, but I am still moving forward.

Close-up view of the placement of the metal to be bent , the clamping board & the joint between the base board and the hinged board.

Close-up view of the placement of the metal to be bent , the clamping board & the joint between the base board and the hinged board.

To test it I placed the clamp as shown in the first two pictures.  The clamping board was placed at what I consider a reasonable distance from the joint between the bottom board and the hinged board.  Obviously, I did not worry about squaring up the piece to be bent because I was interested in how tight the bend would be.

 

The second bend - Notice how the hinged board is deflecting and making a large gap.

The second bend – Notice how the hinged board is deflecting and making a large gap.

Unfortunately when I made the bend I noticed I had a problem with the hinged board bowing and creating a gap. I did not have my camera in hand to photograph it so I made a second bend in the same piece of metal so I could photograph what was happening.   This gap effectively increased the distance between the hinged board and the clamping board.

An end view of the first and second bends.   The bend radius is much better than the first test.

An end view of the first and second bends. The bend radius is much better than the first test.

This distance did prevent me from get a tight radius.   However,  it is much much better than the first test.  It is still not good enough.

 

 

A top view of the small channel piece I bent.

A top view of the small channel piece I bent.

To put the size of everything into perspective, a ball point pen was included in the picture of the top view of the channel piece I created. All-in-all I am pleased with the results and will continue to put time and effort in this.

 

 

 

The bend from first test when the clamping board slipped backwards,

The bend from first test when the clamping board slipped backwards,

The final picture I am including is the one from the post showing how large the bend radius was in that test.
The next step will be to reinforce the hinged board to prevent it from flexing.  My first attempt at doing that will be to install a piece of 1″X 1″ X 1/8″ angle the full length of the hinged board and test again.  If I need to further stiffen the hinge board this will provide a surface to attach a triangle brace to completely stiffen the board.

Once that proves successful, I will then do a series of tests to determine how close to set the clamping edge to the crack between the hinged board and the base board to make a nice tight bend.   I then will design a better clamping method than using the C clamps.   I may or may not actually build the clamps I design, since I don’t intend on using this brake for production and I can easily live with the c-clamp method for making one enclosure at a time.  I will have to fabricate several sizes of clamping boards to create an enclosure.   I will also have to place the brake in a location where I can put the c-clamps with the threaded side down to keep the clamp out of the way of the box being bent.   — More on that later when we get to it.

Gary

 

 

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Test 2 of The Box and Pan Brake – Making Progress” by Create-and-Make.com is licensed under a Creative Commons Attribution-ShareAlike 3.0 Unported License.

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