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Permalink Reply by Jesse Hartman on September 1, 2013 at 10:18am

I believe that you bend all the same radius until you get up to the  .063 and up.  That what I do. My brake is build with a 3.2mm radius

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Permalink Reply by Gary Lee Weber on September 1, 2013 at 3:15pm

Most of the thicker parts are smaller brackets and such.  I made a hardwood block with the proper radius on the edge.  I sandwich the part blank between two blocks and line up the edge of the block with the bend line.  Once clamped firmly in the vice, I simply bend the part to the proper angle using a mallet.  I've made the elevator control horns and center hinge brackets like this and they have turned out well.

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Permalink Reply by Jim B Belcher on September 2, 2013 at 8:40am

The minimum bend radius for different thickness of aluminum can be found in AC43-13-1B and 2B. Copies can be downloaded here:

http://www.faa.gov/documentLibrary/media/Advisory_Circular/AC%2043....

and here:

http://www.faa.gov/regulations_policies/advisory_circulars/index.cf...

Basically, the thicker the aluminum, the larger the radius you need.

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Permalink Reply by Mike Johnson on September 2, 2013 at 10:41am

Thanks for the help guys!

Mike

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Permalink Reply by Malcolm Hunt on September 2, 2013 at 3:07pm

I used the 3.2mm radius for all up to and including .040" and for .063" bent up two thicknesses of .040" under the brake which worked great.. Using Dave's brake have made all the parts for a 601XL and most parts for a 701SP.  The 7F5-3SP did beat me as it was difficult to stop the part slipping under the brake with the two thicknesses of .040" but other .063" were good.

 

Good luck and if you take your time positioning the material under the brake you will have accurate parts.

 

Malcolm

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