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. 

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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. 👍

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