Bending Sheet stock question

I'd like to know how the scratch builders etc bend sections of sheet with differing radius, the actual process. I am building a sub panel and it has a couple of internal corners that I've managed to bend but I'd like to know how you guys do it, whether over a timber form and then with panelbeatig hammers, vice grips, or what.....I've got no real clue as you can tell from my suggestions. I do have a panbrake bender but it has only one given radius and its not what I want for this project. 

Thanks for the lessons anyone. 

Views: 61

▶ Reply to This

Replies to This Discussion

Permalink Reply by Jim and Amelia Isaacs on May 1, 2025 at 11:53pm

Hi Tony,

I didn’t use a hammer or regular vice grips at all building my kit but maybe they are needed to build from scratch? I would think either of those tools would damage the aluminum. Never needed a slip roll or other similar tools. I used a simple bench mount straight bender, wooden or other improvised forming jigs, ratchet straps, seaming pliers, and fluting pliers to bend the aluminum stock that came with my kit. No doubt You Tube, EAA and Kit Planes have a few how-to videos for anything more complex. Whatcha building?

Permalink Reply by Mel Asberry on May 2, 2025 at 6:47am

To increase the bend radius on your brake, you can bend different thicknesses of aluminum and use these as a "shoe".

Also remember when bending aluminum, always bend "across" the grain.  Bending "with" the grain will almost always cause cracks.

Permalink Reply by Tony Renshaw on May 3, 2025 at 5:28pm
Thanks Jim and Mel, much appreciated and I didn’t know about the grain bending. 👍

RSS

New from Zenith:

Zenith Planes For Sale 
  

Classified listing for buying or selling your Zenith building or flying related stuff...

Custom Instrument Panels
for your Zenith:

Custom instrument panels are now available directly from Zenith Aircraft Company exclusively for Zenith builders and owners. Pre-cut panel, Dynon and Garmin avionics, and more.

Zenith Homecoming Tee:

Zenair Floats

Flying On Your Own Wings:
 A Complete Guide to Understanding Light Airplane Design, by Chris Heintz

Builder & Pilot Supplies:

Aircraft Insurance:

 
 

Transition training:

Lavion Aero

K&S Aviation Services

Aircraft Spruce & Specialty for all your building and pilot supplies!

How to videos from HomebuiltHELP.com

Developed specifically for Zenith builders (by a builder) these videos on DVD are a great help in building your own kit plane by providing practical hands-on construction information. Visit HomebuiltHelp.com for the latest DVD titles.

© 2025   Created by Zenith.Aero.   Powered by

Badges  |  Report an Issue  |  Terms of Service