To "brake" metal means to bend it; a metal brake is a handheld device that bends metal. Dies and fixtures are used with the brake to create a variety of bends and angles. To make a metal box, you could attach six different pieces of metal. But with a metal brake, you can make a box from a single piece. Here's how it's done. Materials:
Square piece of sheet metal
Marker
Metal snips
Metal brake
C-clamps
Drill
Rivet gun
Rivets
Drill bit the same diameter as the rivets
- Use a marker to draw lines in the metal where you want to bend it (figure A).
- Use metal snips to cut one line on each corner of the metal to the point that it intersects with another line (figure B).
- Place the metal on the brake's platform, and align the point to be bent with the seam on the platform. Place the brake bar on top of the sheet metal. Use C-clamps to tighten the brake bar (figure C).
- Pull the levers on the metal brake to an upright position to make the bending point (figure D).
- Loosen the C-clamps and repeat steps 3 and 4 to make additional bends on the remaining sides of the metal.
- When folded, the box will have protruding squares of metal. Fold each of these to the outside of the box, against the sides. Drill a hole through each corner of the box as pilot holes for the rivets (figure E).
- Use a rivet gun to rivet the corners of the box to secure the sides (figure F).
A Jig for Creating Decorative Curves You can also make decorative bends and curves in metal. A homemade jig can help you bend sheet metal to almost any desired shape. Here's how to make and use it. Materials:
Band saw
Circular or oval piece of wood, any size
Steel strapping the same width as the height of the wood
Drill
Screws
Scrap piece of flat wood, larger than the circular or oval piece of wood
Sheet metal
- Use a band saw to cut a curve or large groove in the circular or oval piece of stock (figure G). The size and shape of the curve are up to you.
- Wrap a piece of steel strapping around the edge of the jig, and screw it in place. Screw the jig in place on the scrap piece of flat wood (figure H).
- Wrap sheet metal around the circumference of the jig and into the curve or groove (figure I). Continue wrapping the metal until you've bent it to the desired shape.
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