Bending aluminum angle

[Michael Carter]

How can I bend 3/4" 90 degree aluminum angle around an inside corner without a brake?

I need this for the 3# window frame in the cockpit.

I bent some before by cutting a series of notches but it didn't look too nice. Fortunately, it was for the upper instrument panel support and can't be seen, but this is going to be in plain view and I want it to look correct. And nice.

Any ideas?

[Trevor Hale]

How can I bend 3/4" 90 degree aluminum angle around an inside corner without a brake?

I need this for the 3# window frame in the cockpit.

I bent some before by cutting a series of notches but it didn't look too nice. Fortunately, it was for the upper instrument panel support and can't be seen, but this is going to be in plain view and I want it to look correct. And nice.

Any ideas?

I would suggest back-cutting the angle iron with a cutoff saw in several locations, or alternative to that would be use a different material, ie (Corner bead for drywall etc. something that bends much easier. Then the material you cover it with (plywood etc, would be used to strengthen it.

Trev

[Michael Carter]

The corner bead idea sound like it might work if I can find it without holes.

The angle will be exposed though and won't be covered with anything other than paint. It also has to be strong enough to support 1/2" plexiglass attached to it.

Is there some mathematical solution to knowing where and how wide the back cuts have to be for a given angle so the edges of the cut sections will all be together when the angle is bent?

I think either way this is going to look like crap. I'm going to have to find another solution to this problem. I wish Boeing would have squared those window corners.

[Jackpilot]

Mike
Go to any car junkyard and find the most appropriate window frame moldings...(vans have good ones). Besides they can be cut to size (plastic) even heat bent.

[Michael Carter]

Whoa, now there's an idea. Thanks.

I'm cooking up something right now in the shop that might work.

[Michael Carter]

There's more than one way to skin a cat:





Cut from one piece of ABS sheet plastic and one sheet of aluminum roof flashing. Same way my throttle is skinned. Don't know why I didn't think of it before.

Who knows, Boeing may have stamped these corners out of aluminum or steel.

Anyway, this will work.

[Westozy]

Hi Mike,

A sheet metal shop should be able to roll your angle, I know it can be done with steel.

Gwyn

[Michael Carter]

Thanks Gywn, I think this will work out OK: