Cutting/bending sheet metal

[Egon Spengler]

I'd like to buy some sheet metal and cut it to shape for some armor.

Whats a good 'gauge' metal to use? 22 was pretty good when I saw some at home depot but I'm not sure how I would cut it.

Also I'd like to bend this to shape too. How would I go about doing that? Should I heat the metal first? Can I use a blowtorch to heat it enough to bend it depending on the gauge of metal? I'm not looking to make too many sharp bends in it.

 

[jakob2121]

I use a nibbler. I swear by it, even if it takes longer than a dremel would. Most of the nibblers I've seen use a crescent shape, but Radio Shack (of all places) has one that is square. Once you get the hang of it (or get an air-powered one) it goes pretty quick. Just keep it oiled.

Bending metal is just something you get used to. I'm constantly being asked to fix glasses and the like now, because once you get the feel for bending metal (without breaking it) you can bend just about anything into it. One day I hope to learn how to use an english wheel, but...a man needs a goal.

Anyway, I cut through .065" aluminum tubing no problem with the nibbler I got from RS, so, I don't think the thickness that you're finding will be an issue.

 

[GuntahKela]

I've cut metal sheets with a jigsaw. I know it is a power tool, but it gets the job done. I can only suggest you watch a few episodes of American chooper and Monster garage to give you an idea of banging metal sheets on a pillow and rounding it smooth. Search on youtube for videos.

 

[Egon Spengler]

<div class='quotetop'>QUOTE(jakob2121 @ Feb 7 2007, 05:53 PM) [snapback]1414078[/snapback]</div>

I use a nibbler. I swear by it, even if it takes longer than a dremel would. Most of the nibblers I've seen use a crescent shape, but Radio Shack (of all places) has one that is square. Once you get the hang of it (or get an air-powered one) it goes pretty quick. Just keep it oiled.

Bending metal is just something you get used to. I'm constantly being asked to fix glasses and the like now, because once you get the feel for bending metal (without breaking it) you can bend just about anything into it. One day I hope to learn how to use an english wheel, but...a man needs a goal.

Anyway, I cut through .065" aluminum tubing no problem with the nibbler I got from RS, so, I don't think the thickness that you're finding will be an issue.
[/b]

Thanks. I'm not sure what you mean though. When I looked for 'nibbler' on the radio shack site these came up
http://www.radioshack.com/search/index.jsp...ibbler&sr=1

 

[jakob2121]

<div class='quotetop'>QUOTE(DarkLordVader @ Feb 7 2007, 05:23 PM) [snapback]1414100[/snapback]</div>

Thanks. I'm not sure what you mean though. When I looked for 'nibbler' on the radio shack site these came up
http://www.radioshack.com/search/index.jsp...ibbler&sr=1
[/b]

Yup. That's what I was talking about. If you have a decent air compressor, the air-powered ones you can get from a tool shop are a dream. But if you need something you can use wherever, those are the ones I was talking about.

 

[DemonSeed]

therye called hand tongs
and you can get them at ac supply houses.

 

[cheech9898]

<div class='quotetop'>QUOTE(jakob2121 @ Feb 7 2007, 10:53 PM) [snapback]1414078[/snapback]</div>

One day I hope to learn how to use an english wheel, but...a man needs a goal.

[/b]

I haven't seen one at the local Harbor Freight yet but I noticed this on their website the other day

http://www.harborfreight.com/cpi/ctaf/disp...temnumber=95359
http://www.harborfreight.com/cpi/ctaf/disp...temnumber=95366

For the price and for light hobby type use it probably isn't too bad & I would have probably gotten that if it was released a few weeks earlier. Instead I used x-mas gift cards to Eastwoods and got the weld-up E-wheel kit and bought the steel tube to make the frame 2 weeks ago. I always seem to have poor timing thou :lol

 

[Ogibendogy]

I cut off tool is a fairly easy and very quick way to cut metal. They are affordable too. I also suggest a bench grinder for dressing the cut edges. These are very affordable.

Regarding heating the metal, I don't think you'll need to. If you're looking to make sharp and/or straight bends, a bending brake is a great tool (like this one: http://www.grizzly.com/products/g9950 )

Marc

 

[TFrosst]

No heating required and I wouldn't recommend a jigsaw for steel that is of a light guage like that. You'll distor the edge of the metal and then have to smooth it back into shape.

One of the best tools you can use is called a Kett shear. It makes a coil of scrap as it cuts and produces a nice edge and doesnt' distort the piece. When it comes to shaping, you need a good hammer and a dolly/anvil of some sort depending on what kinds of shapes you want. If your just doing simple bends in the metal, you can just bend it by hand. If you want to produce a concave or convex shape, you're going to need a hammer (plastic tear drop shaped) and a shot bag to rough it out. You can then use a slap hammer on a dolly to smooth everything out. There are more expensive an elaborate methods, but these are quite affordable. Hand shears are the cheapest way to cut metal of that guage. You'll have a nice edge too.

 

[SmilingOtter]

http://www.arador.com/construction/index.html
http://www.armourarchive.org/

Any information you need that can't be found there - doesn't exist.

 

[Sulla]

<div class='quotetop'>QUOTE(SmilingOtter @ Feb 7 2007, 09:33 PM) [snapback]1414200[/snapback]</div>

http://www.arador.com/construction/index.html
http://www.armourarchive.org/

Any information you need that can't be found there - doesn't exist.
[/b]

Here here. I second that.