Bend Profile for Sheet Metal

Why don't you go for 3D model? simple and quick.

but to make with cardboard, you can form cardboard on on a block having desired profile, paste some resin/glue on it and leave it for drying.

Also why to use cardboard,Some ductile metals like aluminium should work.

Is this a one-off? Can you provide a sketch?

Cut your cardboard to rough fit the concave of the bend, and apply a level, plumb, and square reference grid before temporarily clamping in place. Make a transfer stick, sharp at one end, squared off at the other. place the tip of the stick on the bend, and draw a line onto the cardboard from the top of the stick and across the end. Transfer these points to another piece of material with witness marks (paper, cardboard, plywood is best), and connect the dots with a flexible spline. Cut out to try-fit, convert to CAD, or just give your drawing to the supplier. Don't forget tabs or flanges needed to refit.

Check the bend radius by radius gauge or draw circle on paper match with profile to be bent. Measure the angle by bevel protractor. After bending, what are the dimensions requirement on two sides, If you give supplier can manufacture the same.

It's a poor sheetmetal shop that can't make your product from your cardboard piece. We use cardboard all the time. If you are not going to a sheetmetal shop and some manufacturer then that might be your problem, try going to a sheetmetal shop that does ductwork. If you are then you need to try some other shop. You might try a smaller shop. They are more likey to now the old ways, and not be dependent on computers. If you are any where near Omaha, Ne then take it to The Waldinger Corp and we can do it for you. Ask for Stan or Dave (that would be me).

Good luck

Would it be possible to make a cement/or plaster sim of the finished product then cut and Tig the metal to fit?

Joe In Texas

Hi Fishpipes

I stay in South Africa in a town called Mossel Bay. It's 4 hours drive to the closest city.

The shops around here is few, so most of my supplier's comes from the city's and it's difficult to get them to come out this way. But at last I got one willing enough to come out and help me with my problem and only because I placed the order with them.

Thank for the advice though.

SCOT

is this a replacement part or a new design? bend radi are pretty standard. the only problems come when you want a smaller bend radi than standard. also, the direction of the grain of the metal makes a difference. they are called easy way and hard way. a hard way bend is harder to make a small bend, because the metal tends to crack. sometimes heating the metal at the bend point just prior to bending will help. but if you just want a normal bend, just tell the machinest to use standard bend radi. i don't have my charts handy, but it would help to know the thickness and type of metal. also, bend reliefs at the corners helps to prevent deformation.