Posted by Keith in Washington [172.71.146.165] on Wednesday, January 11, 2023 at 13:31:47 :
In Reply to: metal bending posted by Todd Miller [172.70.211.140] on Tuesday, January 10, 2023 at 16:00:52 :
When faced with the problem you have, I have done this.
1) Figure out how I can make the piece out of multiple pieces.
2) Go to a metal supply shop and have them cut and bend strips with a 90 degree or appropriate angle. I have 4' strips made. I have one side of the strip bent so it is about 1/2" wide (this will be the welding face). Make sure the strips are over sized not the other side. I will use each strip to make one side of the part.
3) I will form each piece into curves, if needed, with a shrinker stretcher set. I also have a small air tool to form an offset for overlap welding.
4) I then weld the pieces together forming the required piece. I put the short 1/2" side of each strip on the invisible side of the part. I have Tig, Mig or spot welded these pieces together.
I have made many complex pieces this way such as the double curved bottom to my carryall tailgate, along with door post boxes and all sorts of other pieces. The key it getting the strips bent correctly. Take the original piece with you to the shop so the can match the bends. Remember that metal is much more forgiving than wood. A wrong cut can be welded.