Bending up a DIY chassis

[Che_Guitarra]

I'm looking to make my next build from scratch, and that involves bending up a chassis. I'm looking to make a tweed style box chassis, the sheet material is likely to be stainless, and i'm wanting to know how I can get clean crisp 90º folds without going to a fab shop or buying $$$ worth of tools.

Any suggestions?

 

[smolder]

With steel? Good luck. Maybe with aluminum and some long wood blocks, but you really need a brake. I gave up on that and found a guy that makes chassis in his spare time... of course right after that his barn burned and he shut down.

 

[Che_Guitarra]

I thought as much. And stainless it tougher to work than carbon steel too.

I might get it cnc cut and bent up professionally - but the less I spend on outsourcing the more I can spend on my own tool kit.

 

[ModdersAnon]

Check into waterjet cutting. Keeps the temp down, so less issues with warping the thin steel.

 

[amphog]

A rule of thumb is reduce the capacity of a brake by 2 for stainless, 16 drops to 18.

 

[Mattbedrock]

My wife has this brake at her shop that I use:

It works great.

If you were a bit closer, I'd be happy to help you out.

 

[zenas]

I've bent metal plenty of times by clamping it and folding it over with a hammer.
I've also seen plenty of guys turn it into scrap metel trying to do it that way.
There's a knack to it and it takes a little time and scrap metel to learn how to get it right.

That said I'll always use a brake if I can. It just works better.

 

[buddyboy69]

Maybe for occasional use, its not too $$$$. I know harbor freight isnt for everyone but somtimes it o.k. for certain things. They have other breaks as well.


http://www.harborfreight.com/30-inch-bending-brake-67240.html

 

[Silent Sound]

I've bent metal plenty of times by clamping it and folding it over with a hammer.
I've also seen plenty of guys turn it into scrap metel trying to do it that way.
There's a knack to it and it takes a little time and scrap metel to learn how to get it right.

That said I'll always use a brake if I can. It just works better.

I do some metal sculptures from time to time and have done much more complex shapes than a box. A couple of hammers, an anvil, and a good heavy duty vice clamp that doesn't mind being hammered on are all you really need. That being said, making a straight bend is not easy with those tools. I'd definitely recommend a brake or taking it to a metal fab shop. But if you're hankering for a challenge and have the time, it could be done. Just take it slow. Real slow.

Never mind. Buddyboy69's link would be a better choice. I didn't know you could find a brake so cheap. That's cheaper than a good anvil or vice, and a LOT easier to use.

 

[smolder]

Oddly, the local harbor freight is next door to the guitar center.

I would not want to attempt steel with that break.

 

[LPVM]

Oddly, the local harbor freight is next door to the guitar center.

I would not want to attempt steel with that break.

Stainless too. The only thing that would bend would be the brake.

 

[zenas]

One thing about stainless is it work hardens. So if your drilling it with a hand drill it can be a royal bitch.
A drill press and a good bits help alot.

 

[TimmyP]

When drilling steel, especially stainless, use firm pressure, a slow speed, and a drop of oil.

 

[Member 1963]

Migh think about scoring it first, tho thats more likely to work with aluminum.

 

[xtian]

With aluminum, you can use a table saw to score the bends. Makes the bends straight and much easier. Then weld the corners with alumaweld.

 

[Kyle B]

Check the local rental places. I bet you could rent a good brake for not much $$$

 

[ked]

I built the metal brake in the link below. It is sturdy enough and has the leverage to build just about any kind of chassis. If you don't mind a little cutting and welding, this is an inexpensive table top brake.
http://www.majorleagueduning.com/tech/Brake/Brake.htm

Ken