End view of the brake showing the clamps and end of the radius board, the bending bed and the bending hinge. There are 6 - 3" Stanley door hinges on 12" centers. I tried larger hinges... don't waste your time and money... 3" are ideal and work the best! The brake is 5', but can be used at the end of a 4' wide table no problem.This started out as an 8' brake and after a few iterations wound up as a 6" brake(yes 6") after many screw ups and 2 years... I forgot to try a keep it simple. The bed surpports are 2 x 4 - 10" peices on 12" centers at each hinge location! The handle is 16" and just 2 - 2 x 4 and 1 - 2 x 3 spruce and a box of 2+1/2" #10 wood screws. The handle could be longer... say 24" that way you would have a loger moment arm, thus less force, but the 16" works fine. The "L" angle you see is 4' x 0.032 and I had no problem bending.

This brake is long enough to bend all of the parts under 5' for the 701 build... I will finally get to build an 8' or 10' for the longer stuff but right now this one is a keeper this time!

If you are not sure if it will work for you... start out small - 6" and 1 hinge is all it takes to get you going... and once you get it right, then just add on to whatever length you choose! Just don't start backwards like I did... and DON'T use anything other then Solid Clear(no knots) Douglas Fir! Almost forgot, just to give you some idea how tough D.Fir is... I went through 4(yes 4) - 1/8" dril bits, each screw hole has to be drilled full length otherwise the screw will just not go in. When it starts to smoke then chuck the bit and use a new one as it will break off in the hole... been there, done that!!!

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Comment by Ron D Leclerc on August 13, 2011 at 7:17am

Hey Darren...

Good to hear from you!   Well it took me 2 years before I was able to figure it all out! Started out with an 8' brake... screwed that all up so I walked away from it!  Tried agin and had to scrap!   So I finally smartened up and built a 6" one and one 3" door hinge... tried hinges that were huge to big at first, the 3" ones(Stanley) works the best.  They are some kind of hardened steel... cannot drill I tried and strong as hell!   I then came upon one built by the late Bob Hoover and that was where I found out to keep it simple and... low and behold it worked beautifully.  That "L" angle in the photo came out just as staright as can be!   The key is the strips of duct tape on the bed and radius board... holds the aluminum place and does not allow it to bow out or bend!  That was one of the problems that I had at first... keeping the bends straight!

Ron

Comment by Darren Stevenson on August 13, 2011 at 6:35am

Ron,

Great brake. Another "Why didn't I think of that!"

Darren

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