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Sheet Metal Brake

Plans

Build Your Own


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Here is an inexpensive and easy way to build your ownSheet Metal Brake. It is a nice little weekend project. I have

put a great deal of thought onto this design.

I have built 3 different proto types and found some roomfor improvements. So I redesigned it until I found it to be

perfect for my needs.

It was designed to bend aluminum up to 6feet wide and.040 thick. The last one I built I used to build my own little

motorcycle trailer and it worked great.

I have included in these plans a complete material listwith instructions, illustrations, and photos. My goal here wasto put these plans together so that anyone could understand

them.

You do not have to be an engineer to read these plans.You can also print out the pages you need which make it

convenient to take to the garage with you. I hope you will findthe plans easy to follow and I hope you enjoy building your

own.

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Hello since we designed these plans

some things has certainly changed.

This includes the price of steel.Most of the material needs to remain

the same however I have re-designed

the legs using a smaller size angle.

In the material list on the next

page you will see at the top of

the page the 3 X 3 X angleExample below:

UANGLE

U(Quantity U) USizeUUMark

(1) - 3 x 3 x x 76 - #1

(1) - 3 x 3 x x 76 1/8 - #2

(1) - 3 x 3 x x 72 - #3

(2) - 3 x 3 x x 31 - #s 4A & 4B

(2) - 3 x 3 x x 28 - #s 5A & 5B

(2) - 3 x 3 x x 2 - #s 6A & 6B

The four pieces shown here in red (2)

pieces 31 long and 2 pieces 28 long are

the ones you can alter.

We are now using 2 X 2 X 1/8 thick

angle and it is working great. It is also a

good bit cheaper than the 3 X 3 X thick angle.


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Cut the pieces to size and mark them with the piece numbers (on the right) out from the

dimensions shown here:

ANGLE

(Quantity) Size Mark

(1) - 3 x 3 x x 76 - #1

(1) - 3 x 3 x x 76 1/8 - #2(1) - 3 x 3 x x 72 - #3

(2) - 3 x 3 x x 31 - #s 4A & 4B

(2) - 3 x 3 x x 28 - #s 5A & 5B(2) - 3 x 3 x x 2 - #s 6A & 6B

ANGLE

(1) - 1 x 1 x 1/8 x 75 - #7

FLAT BAR

(1) - 3 x 1/8 x 60 - #8

FLAT BAR

(4) - 2 x 3 x - (2) #9s (2) #10s

COLD ROLL

(2) - 5/8 x 18 - #11

(2) - 5/8 x 2 - #12

(4) - 4 Swivel Casters

(2) 3/8 x 2 Course Thread Socket Cap Screws

(4) 3/8 x 1 1/4 Course Thread Bolts(4) 3/8 Flat Washers

(8) 3/8 Nuts

(4) 3/8 Lock Washers

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STEP # 6

Take the End Caps (2pcs) 2 x 3 x 28 (Marked #s 6A &6B) Cut out the notches on opposite corners as shown.

Illustration # 7 and Photo #6

STEP # 7

Now take the Hinge Plates (2pcs) 3 x 2 x (Marked # 9) Drillthe 5/8 holes through as shown.


STEP # 8

Take the Clamping Plates (2pcs) 3 x 2 x (Marked #10) Drillthe 5/8 hole through as shown.


STEP # 9

Take the Hold Down Clamp (1pc) 3 x 3 x x 72 (Marked#3) and take the (1pc) 3 x 1/8 x 60 (Marked #8). Measure and

place on an angle and stitch weld as shown.


Now that you have all the pieces cut and drilled you will need toclean all the edges for safety.

We are ready to start the assembly.

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STEP # 10

Leg & Foot AssemblyYou will need the legs #s 4-A & 4-B and the feet #s 5-A & 5-B. Take#4-A and 5-A and line up as shown in illustration # 11 and Photo # 10.

Weld where the two pieces join together shown in Photo #10-B. You willdo the same with #4-B and 5-B with one exception, you turn the leg to

the opposite side as shown in Illustration #12

STEP # 11

Next we will add the casters to the leg & foot assembly unit. You havetwo options you can weld them on, or bolt them on its your choice. To

weld them on you lay the unit down as shown in Photo # 13 and positionthe caster evenly, one on each end. Use a C-Clamp to hold in place andweld around edges as shown in Photo # 13. To bolt them on you will

need to drill the holes appropriate for your casters, as the boltholepatterns will vary on different casters. Do the same with the other leg &

foot unit.

STEP # 12

Next we need the Main Frame (1 pc) Marked #1, we will also need (2)3/8 Bolts, (2) 3/8 Nuts, (2) Hinge Pins #12. Turn the Main Frame #1

over as shown in Photo #14 and put the bolts up through from theunderneath, place the nut over and tighten until firm. Now weld the nut

to the frame as shown in Photo # 14-B. Do the same on both ends.Leave the bolt in and turn over the Main Frame #1 (the photo does not

show the bolt in the hole, however we decided it should stay inthroughout this procedure to keep the hole free of weld splatter). Take

your Hinge Pins #12, one goes on each end. Place it back as far as you

can keeping it flush. This is very important that you make certain thatthe pins lay completely flush on the main frame. Use a C-Clamp to

secure them for welding as shown in Photo #15-B. Leave the C-clampson until the weld cools completely to prevent any pulling. You can

remove the bolts now.

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STEP # 16 Cont.

Now we are going to attach the Hinge Plates (2pcs) 3 x 2 x (Marked #9). Place the Hinge Plates over the Hinge Pins (this is a tight

fit, you might have to use a hammer to tap in place). Make sure theplates are squared with the Main Forming Angle and weld as shown in

Photo # 19-C. Be sure you see the notice on Photo # 19-C. (Do not weldpast the point shown in the photo). You can now remove the C-Clamps.

STEP # 17

Take the Clamping Plates (2pcs) 3 x 2 x (Marked #10), (2)3/8 Socket Head Cap Screws, and (4) 3/8 Flat Washers. Place the firstwasher over the socket head cap screw and place through the Clamping

plate and place a second washer over the bolt and spot weld the secondwasher in place as shown.

Illustrations #13 & 13-B and in Photo #21-A

STEP # 18

Next get the Clamping Plate #10 and the Hold Down Clamp Unit andthe Main Frame Unit. First take the Hold Down Clamp Unit and sit it on

top of the Main Frame Unit as shown in Photo #20. You will place theHold Down Clamp Unit back .040 from the front edge of the Main

Frame Unit and 1 back on each end as shown in Photo #20-A. Nowplace the Clamping Plate on the end of the Hold Down Clamp Unit.

Line up the bolt in the 3/8 hole in the Main Frame and also square upthe side with the edge of the Hold Down Clamp Unit and weld as shown

in Photo #21-B.

STEP # 19

Take the Handles (2pcs) 5/8 x 18 (Marked #11), turn the MainForming Angle up as shown in Photo #22 and clamp one Handle on

each end to the End Caps of the Main Forming Angle. Lining it up withthe Hinge Plate and the bottom of the End Cap as shown in Photo #21-A

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5/16"

5/16"5/8"

Side View

1"

5/8" 2"

2222

End View

#12

(Machine) Cut out the area 5/16" X 1" as shown here markedThese are the most important parts you will need to be sure omeasuring and machining. They are what lines everything up

pieces to bend even and square.

Illustration #1

Hinge Pins - 5/8" X 2" Long - Cold Roll (2pcs mark


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1"1"

Main Frame - 3" X 3" X 1/4" X 76 " Long (marked # 1)

76 " Long

1 1/4"

3"

#1

Illustration #2

.Drill 3/8" HoleThrough

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3/4"

3/4

3"

3

3/4"

Cut out theseportions 3/4"

Down & 1 1/4"Over both sides

and on the oppositecorner

Side View

2

#2

76 1/8"

Photos of the completedpiece follows on the next page

End View

22 22

Main Forming Angle - 3" X 3" X 1/4" X 76 1/8" Long (Marked #2)

Illustration #3

1 1/4"


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31"

1/2"

#4-A

2

Legs - 3" X 3" X 1/4" X 31" (2pcs Marked # 4-A & 4

Illustration #4

1/2" This is the legs 2 pieces marked #'s 4-A & 4-B. you will need to make two cutsshown above. This first one we will show is the releaf angle. Measure back1/2" and up 1/2" at one corner join marks and cut this angle off as shown.

The second cut is a 3/8" releaf on the opposite end from the angle releaf.

You will need to measure back 3/8" all the way up and then 3/8" overthe back edge as shown and cut away.

On the piece marked 4-B you will need to cut the angle and the 3/8" releafon the oppsite ends as shown on the next page


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As described on the previous page on #4-A and #4-B you

cut the 1/2" releaf angle on opposite ends. You will also cutthe 3/8" releaf on opposite ends from the 1/2" releaf angleas shown here. There are photos to show the releaf angleand 3/8" releaf on the next page

#4-A

#4-B

31"

Legs - 3" X 3" X 1/4" X 31" (2pcs marked #4-A & #4-B)

Illustration #5


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On #5-A you will need to measure and mark over12 1/2". On #5-B you will measure and mark from the

opposite end as shown in the drawing here. This isto line the legs up when we begin assembly. Go

ahead and set these aside.

Illustration #6

#5-B

#5-A

12 1/2"

28"

Feet - 3" X 3" X 1/4" X 28" (2pcs #'s 5-A & 5-B)

12 1/2"


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3/4"3/4" 3/4"

3" 3"

3"3"

2 1/2" 2 1/2"

2 2

#6A #6B

Illustration #7

Cut out the 3/4"places as shown

markedhere withan X

End Caps 2 1/2" X 3" - ( 2pcs marked #6-A & 6-B)

3/4"3/4"


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Drill 5/8" Hole

Through

Front View

Before you drill the 5/8" hole it would be

a good idea to first drill a pilot hole witha 3/8" bit first to insure you get a true5/8" hole.

Illustration #8

Hinge Plates - 3" X 2" X 1/2" (2pcs marked 9)

#9

1/2"3"

1/2"

1/2"

2"

5/8"


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3" 1/2"

2"

5/8"

1"

#10

5/8"

Illustration #9

Clamping Plates - 3" X 2" X 1/2" (2pcs marked #10)

Drill 5/8" HoleThrough

Before you drill the 5/8" hole it would be

a good idea to first drill a pilot hole witha 3/8" bit first to insure you get a true5/8" hole.


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72 1/2"

3"

3"

6 1/4" 6

5/16"

Stitch Weld Here

60"

Weld Here

#8

#3

#8#3

Illustration #10

3" X 3" X 1/4" X 72 1/2" - Marked #33" X 1/8" X 60" - Marked #8

Hold Down Clamp

Set the Flat Bar5/16" back from thefront edge as shown

here and 6 1/4" overfrom each end andstitch weld.

5/16"


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#4-B

#5-B 12 1/2"

Leg and Foot AssemIllustration #12

Photo # 10 shows the leg assemblPhoto's # 11 & 12 show a close viethe welding on next page.

This Leg and Foot Assembly will beput together the same way as thefirst one with the exception of turningthe leg to the opposite side as shownhere in this illustration #12

Place Leg #4-B and Foot #5-B

together as shown here making sure

they are square and weld where the jointogether.


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Top of P

Bottom of

3/8" SocketHead Cap

Screw

3/8" Washer

3/8" Washer

2" X 3" X 1/2"Clamping

Plate

Clamping Plate Assembly


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3/8" SocketHead Cap

Screw

2" X 3" 1/2"

Clamping

Plate

Spot Weld

Around This

3/8" WasherAs Shown

Spot WeldAround Thi

3/8" WasherAs Shown

Clamping Plate Assembly


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Now that your Brake is

completed you can paint it

any color you want.

This is what yourcompleted project

should look like.

Enjoy!

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