I have been trying to make some windscreen (aeroscreen) supports from 5mm aluminium sheet. I cut the shape out fine but bending them is proving difficult. I have managed to bend them to almost the right shapes however I cannot get a smooth curve on them and currently have curves that are angular. Diagram A shows what I have and B what I would like. The supports are nearly there but just need that nice curve to make them fit perfectly. Anyone got any tips ?

thanks

[Edited on 27/5/04 by givemethebighammer]
Rescued attachment winscreen supports.JPG

I'd suggest a former. Bond several pieces of MDF together to make one piece that is thicker than the width of you supports.

Cut the edge to the shape of the profile you need. Firmly clamp one end of the support to the former and hold the former in a vice. Bend the support to the shape of the former using a soft faced mallet or hammer and piece of wood.

Usually works for me.

You'll probably have to hit it hard but it will go. Do the sharp bend as a seperate operation.

[Edited on 27/5/04 by DavidM]

a bit less accurate way is to bend it over somthing curved ie a pipe, scaffold pole etc. slowly form the curve a bit at a time by bending the ali by hand.either clamp both the pipe and ali in a vise or use somthing fixed in the past iv'e used fences or sign posts anything with the correct radius.

I used a variation of nick's where I clamped two 30mm pipes about 10mm apart and formed a gradual bend on the support by bending a bit at a time moving the support to suit. Time consuming, iterative but effective.

I bent mine in a vice, by moving it up slightly each time, once polished they both came out fine

have you tried softening the alu by annealing it?

atb

steve

Go on Steve- tell us how you do it!

James

this months Which Sh1t pg 98 middle 2 photos. Shows a leugo stainless one being bent.

quote:

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Originally posted by James
Go on Steve- tell us how you do it!

James

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I'm not coming to your house for a shower

Clamp it to an Argon bottle and beat it with a rubber mallet. Simple, brutish - effective

quote:

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Originally posted by Mark Allanson
Clamp it to an Argon bottle and beat it with a rubber mallet. Simple, brutish - effective

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