A project of Volunteers in AsiaAT MICROFICHE REFERENCE LIBRARY Machine for Sheet Metal Work How to Make a Folding by : Rob Hitchings Published by: Intermediate Technology 9 King Street London WCZE 8HN United Kingdom ,:/ Publications, Ltd. Paper copies are $ 3.75. Publications, Ltd. ic, ;; ;,,,:z $:,,;, :p;.;y :, _,jl !,,,d, ,u: 4 Available from: Intermediate Technology 9 King Street London WC2E 8HN United Kingdom Reproduced Technology by permission Publications, :,: of Intermediate Ltd. Reproduction of this microfiche document in any form is subject to the same restrictions as those of the original document. How to make a folding machine for sheet metal work Rob Hitchings This manual, How to make a folding machine for sheet metal work, gives full details on how to build and use a versatile machine for working sheet metal. Such a machine offers the increased facility of being able to readily produce items in sheet metal such as ducting, steel boxes, trays and agricultural equipment. It is equally useful for vehicle building and repair work. Designed specifically for construction from readily available steel sections, the machine could be btilt by most small metal workshops and blacksmiths. The ability to make locally, equipment for small farms and villages in rural areas, is being increasingly seen as very useful, both in the developing countries and in the more industrialized nations. With the rising cost of fuel for transportation and growing awareness of the finite rescources of the planet, it makes sense to encourag-; : :~4 self reliance and small-scale production of certain equipment. * The clear illustrations and step-by-step building instructions make this a very practical manual for any small workshop wishing to increase its capacity to fabricate in sheet metal. The Author (who also illustrated and layed out the pages for this manual), has a background in ‘practical’ engineering and appropriate technology workshops. His business (APT Design & Development), based in Cumbria (N.W. England), design and make village scale equipment for workshops both in the developing and industrialized countries. Rob Hitchings is interested to hear from other designers/engineers who are building similar equipment around the world and hopes that a network of people may emerge who can share ideas and collaborate together to develop further designs. Intermediate Technology England. Publications Ltd., 9 King St., London WC2E 8HN, ISBN 0 90303I 76 0 .HOW TO MAKE A FOLDING MACHINE FOR SHEET METAL WORK Designed and written by Rob Hitchings Step-by-step instructions how to build a versatile machine for folding sheet Intermediate Technology Publications Ltd. K. U. @./. Centre punch through pattern on dots at-d pivot centre. Tapem to metal. Nottingham.I 0 Intermediate Technology Publications 9 King Street. Their assistance is gratefully acknowledged. London WC2E 8HN Ltd. 2 . ! I I i I ! ! --. ‘2 ‘. 1981. ‘. \ Pattern for cam refer b page 24 Cut out square.--. 3p+---.----.Acknowledgements Financial assistance in the final development of this machine as well as in the production of this booklet was made available through Intermediate Technology Industrial Services from a grant from the Overseas Development Administration. ISBN 0 993031 76 0 Printed by the Russell Press Ltd. angle and hollow steel sections using basic welding and fabrication techniques. It can be made from readily-available channul. The only equipment essential to its construction is a drilling machine. chimney flues. air-ducts. funnels. Once constructed. This foiding machine should prove an invaluable tool in any small workshop industrialized countries. or agricultural equipment such as seed-hoppers. cabinets. in the . An angle grinder. is cheap to build and versatile in use. water and fuel tanks. this machine will he found very useful in any small metal workshop to make objects in sheet metal such as boxes. mechanical hacksaw and a ilame cutter would make it easier. trays. an electric cvelder. channels. The machine can be bolted on to a strong bench or mounted on a stand. Construction can be modified to suit locally-available materials. though these tools are not essential. as well as in the Third World. troughs.The sheet metal folding machine. the consiruction of which is described in detail in this bookfei. G clamps and basic hand tools. baking-pans. . Contents Page introduction Uses cf tne machine Description Detail drawings of machine components Construction Operation Optional designs 3 6 7 10 12 27 29 i’,,: :,,,i ::,, 5 &es’ of the folding ‘machine The machine will bend steel sheet up to 16 guage (approx. 1.5mm thick) x 1 metre wide and can produce both box sections, and pans up to 1OOmm deep (150mm on modified machine). Once the basic machine has been built it can be adapted in numerous ways to do almost any sheet metal folding job (within the capacity of the machine’s strength). Several adaptations are suggested in the optional design section. Some of the shapes and suggested items which this folding machine can produce are illustrated below. Box sections: air ducts, chimneys, structural work. Pans: boxes, trays, lids, troughs, water/fuel tanks. Funnels: Grain/seed hoppers etc. Large boxes/tanks 6 which is suitably fixed down.Description The machine comprises: .Two clamp assemblies.The folding beam which is pivoted at each end. ._.__ . The clamps slide from side to side to adjust to whatever width needed. Several clamping beams can be made to suit the widths of four-sided trays/pans required. or for normal straight folds. clamp assemblies clamping beam base frame assembly -&g&g folding beam assemblyw Fig. which act on ._. This has a handle which is raised and thus causes the clamped sheet metal to bend.___ the clamping beam.1 . which clamps the sheet metal along the line that requires folding. In such cases the full width beam can be used. .The base frame assembly. This is not necessary for box sections (ducting). and two mounting plates. strip and two end plates. BASE FRAME ASSEMBLY This is made up of four separate fabrications: the fixed beam. notched at each end to allow for the pivot pins. and comprises a piece of angle. 8 D . and hold the fixed beam and clamp slide together. It is also. They also provide the pivot location for the folding beam. and a piece of angle iron welded underneath to add rigidity. This has recesses cut at each end for the pivot pins which are welded on Dl.3 FOLDING BEAM ASSEMBLY The folding beam is a plane piece of 100 x 50mm channel.Note: All alphabetical letters on this and subsequent pages are also referred to in the detail drawings on pages 10 and 11. D2 The handle is of heavy iron pipe welded to the bottom side of the channel. the clam:. A The fixed beam has a plate welded in each end. Dl D2 Fig. C The mounting plates are heavy angle iron which serve to fix the machine down. slide. B The clamp slide serves to take downward pressure as the clamps are tightened. 9 . They operate as follows: The lever (K5) is pushed down and turns the cam. so called).CLAMPING ASSEMBLY The clamping beam F can be made in a number of ways. This is to allow the steel sheet to be bent further than 9o” so that it can spring back to a right angle. As will he seen from the sectional drawing below they are offset. causing the clamp rocker to apply pressure to the top of the clamping beam. The fixed beam channel wants to turn but it is held firm by the side mounting plates. The result is that point Y puts pressure upwards on the back of the fixed beam channel. but the simplest is to weld two pieces of angle together.5 The clamp assemblies G. Fig. and point 2 puts pressure down on the clamp side. They are made from 50mm box section (square hollow section. H and K are designed for quick grip and release action. 60 I 60 50 I I1 1300 j-1 65 0 7 Cl 32 370 60 100 n M&F2 1220 Components D and D2 are drawn here Vi scale. all the other components are Vi scale. . Gin 170 50 73 015 G446 so . 2.P 7. ‘/ scale. 24 w H8- 90 H7: y” H8z O6 H8 cNFzra?lv 70 0 46 Kl mlo 46 K20 IO 60 i24 3 K3m 26 n2’ 19 K400 13 IS 01 12 K5 250 ‘~ ‘iK6 Detail Drawings of Machine Components Showing suggested side view and sections. Dimensions in mm. . flat angle (MS.S. angle 60 25 x 60 5 x x1300 5 x 1300 M.Construction BASE FRAME ASSEMBLY PARTS Part Name Fixed beam Fixed beam end plates Fixed beam reinforcing angle Clamp slide Clamp cap Clamp slide end plates Pivot blocks Mounting plates Quantity Dimensions (mm) it1 A2 iI 82 El : 1 1 : .S. channel 90 x 40 x 8 M. M. = Mild Steel) .S.S. flat SO x 60 x 1270 M. 100 x 50 x 1300 MS. flat angle 60 x60 x 5 M.S.S. M.S. flat 65 x 80 80 65 x 370 12 M. BASE FRAME ASSEMBLY Cut channel A.That means put short runs of welds (approx. 25mm) at intervals of about Stlmm (in this case). 1 . angle B and flat 61 to length accurately and file ends square in all planes. Position carefully and ‘stitch weld’ in place. Clamp in position just short of channel end and weld in place on inside only. - Fig.Yt to see how this fits. File smooth.7 Mark out and cut pivot recesses. Fid Cut angle AZ to fit in betieen end plates. Study cross section tFig. Do not drill and tap yet Fig.9 13 . Cut end plates Al and file to fit inside channel.-. ‘Stitch weld’ . Stitch weld flat Bl on tca snare -. Clamp to mounting plates and locate hole with piece of 3mm dia. on inside. ‘.Position ..pack the .10 plates C. .1+. . with thin steel and clamp. cut out and clean up edges.~ B *~~ ^_A wero ____1_1 eno prams sngnuy m nom me ena or me angle tlmm will do). Note: Do not enlarge the holes yet. . welding on the pivot blocks 14 ..~^1 ..~ .__I _.-‘.. ano ma end ula. ~. arru . rod. .==. Fig. Drill hole 3mm. Clamp.CI. s uo in not arm stitch welding the clamp slide Mark out accurately and cut the mounting holes with 3mm drill.~L. Weld front and top edges only.flat B!. Centre punch and drill all Mark out pivot blocks Cl....1-a ye. Take a piece of 50 x SOmm square hollow section (the same as will be used for the clamp base HI and H2) to make sure that it will slide along between angle and.Mark out and cut clamp slide end plates (82) and file to fit inside angle B with flat Bl resting on top. Drill holes through into end plates Al and 82. size -. -the two mounting plates are in the same plane (look along them from one end as indicated). Drill to all holes in mounting plates C. speed and lubricant). Remove all clamps. for the ends of the fixed beam. Leave assembled. and _a use .most important .a 3mm drill inserted in the pivot hole lines up exactly with the corner of the fixed beam (Fig. (Sharpen first. Break tack welds with chisel and clean off. and Set UP the base frame assembly using packing and clamps. . Tap up the fixed beam gently with the hammer until this position is exact.121. Check now that the base frame assembly will bolt together properly. setting up the base frame before drilling Fig. -the top of the fixed beam is level with the underside of the flat Bl.12 Tack weld in place if necessary in order to remove clamps for drilling. File holes out slightly only if necessary. Check e drill * * e mar you nave a prece or rouna oar ror me pivots me same srze as you are anrkng. 15 .Mark out on the end plates the positions the clamp slide. _. Note: Take care that the pivot hole is accurate and at right angles to the Fomting a~ plate. and ensure that: -all ends are in position. then tighten clamps. Drill and tap holes in end plates Al and 82.slow _. 13 Cut the two pivot pins D and chamfer ends.S. Position pins in holes in pivot blocks.S. = diameter See diagram on page 7 FOLDING BEAM ASSEMBLY Cut main channel D and file ends square. x SO M.and cut .S.W&lSNG BEAM ASSEMBLY - Part El D2 Name Folding beam Pivot pins Folding beam handle Quantity 1 l5 Dimensions (mm) 100 x 50 x 1299 M. Mark out . It is best to cut on the short stde and file the prvot pin slightly as recesses for pivot pins Fig. tie folding beam is held in place. and the front faces touch ‘gh. channel 20 dia. Clamp in position and tack pins to 16 . Check that it fits easily between the mounting plates on the base assembly.recess for pivot as inzI. and offer up the folding beam D. dia.I~~d. rod 25 nominal bore pipe M. File pivot pins until the two tops of the beams are level. and come to rest right up against the fixed beam. and weld in place. Grind welds and/or fixed beam to accommodate welds as necessary. especially at the outer ends of the folding beam). . Handle . Alternatively. and remove the folding beam. Fig.15 Locate the handle centrally on the folding beam.the down tubes can be square section and the cross piece round. (Make sure these are strong. Complete the welds holding the pivot pins. Build up a good strong weld as this is a point of stress. the handle can be made up either by using some pre-bent tube already available or by welding up elbow pipe fittings. Refit the folding beam into the base frame and ensure that it will rotate freely.If pipe-bending equipment is available the handle can be made as shown.Unbolt one end mounting plate. If not. CLAMPING ASSEMBLY sub-assemblies clamp rocker assembly cam and lever assembly clamp base assemblY clamping beam Fig.17 . filing the leading/folding edge Fig.S. angle 75 x 75 x 1220 M.CLAMPING BEAM PARTS Part Fl F2 F3 Name Clamping beam top half rXafmping beam bottom Stop screw spacers Quantity : 2 Dimensions fmml 75 x 75 x 1220 M.lS F The clamping beam .S. and correct as required.l! . Check that it is still straight. and grind or file the leading edge p. Position off set and stitch weld as indicated. Put in vice or clamp to any sensible fixed object. angle as required F2 F3 Fl Fig.Cut the two pieces of angle Fl and F2. drawing U. MS. Cut the 60 x 5Omm square hollow section as shown and drill the holes for the pivot Gl. with equal amounts protruding each side.20 CLAMP ROCKER ASSEMBLIES Remember to make two of each part whilst marking out and cutting. 50 x 50 x x 73 170 M.i. S. Weld it in place from inside at the front.!..N. 20 . 2 . on x 10 page 11 6 dia..C. 2 : 2 15 dia. bend and file a piece of 2mm plate to fit the front opening and weld in. i_ .<. ‘yi.dia.LA.S. The following describes the fabrication of one rocker.‘. Cut. Cut a piece of water pipe and file to size shown. ROCKER ASSEMBLY - Part El :: G4 :: G? GE Name Rocker body Rocker pivot Rocker top cap Rocker end cap Clamp foot Ca.S. rod $. Rod box 80 x 45 x 2 M.. :..S.:. x 60 approx M. Position centrally at tip of rocker and weld front and back. plate 46 piece x 46 of x27 4 M.S. plate pipe x 80 see drawing on page 11 4 see dia... . O. Fig. Cut the pivot Gl and position through the rocker.Zafollower Screws Return spring pin Quantitv - Dimensions (mm) . It is also easily replaced if wear occurs.(Put screws G7 in whilst welding to avoid getting weld in the threads). Cut piece of brass sheet G6 and wrap around 65.21 Make up cam follower from 1. and drill and file elongated holes. I Fig.5mm steel sheet. . Note: This brass shim can be packed out with more brass or steel shim to increase the clamping pressure.I Cut and file a piece of 3 _ 4mm plate to fit the back opening. and drill and tap as shown. Fit and weld. MS. Ensure front edgs of H2 is a right angle.C.S.S. (A wood worker’s sash clama is aarticularlv useful for this). U.25 .CLAMP BASE ASSEMBLY PARTS Part Hl E E H6 Ii. x 7d approx Fig. flat 50 x 12 10 x 250 18 M.S. x 5 x 25 20 M. flat rod 10 dia. Clamp and weld. flat flat 12 dia.S. box 50 x 12 x 90 M.N.: Ii9 Name Clamp base column Clamp base foot Clamp base tongue Clamp base lip Rocker pivot supports Clamping beam stop screw Stop screw spacer Clamp base return spring pin Rocker return spring Quantity Dimensions (mm) 50 x 50 x 135 180 M. w - Fig.24 CLAMP BASE ASSEMBLY Cut pieces Hl and H2. x 90 6 10dia. cut and drill pivot supports H5. I I Fig. Clamp H3 to H2. 23 . making sure of an extra strong weld at x Mark out accurately.Cut H3 and H4. Set the distance of the lip H4 from the column Hl by hooking on to the back edge of the channel A. Shown here upside down. DO NOT WELD OTHER PIVOT SUPPORT ON YET. Clamp together and weld front and side edges.2 6 Check that the clamped assembly will slide freely from side to side. Remove assembly from the channel and weld foot on to base both sides. Weld in place. Clamp one side to the base and position accurately as indicated. S. M. Finish with a file and check for squareness all roun .rod rod 12 threaded nut Fig. /-- \ Cam profileactual size ‘\ . Centre punch the centre of the cam pivot. . M.S.S..-.-. . Cut profile over size and grind almost to line of dots.28 CAM ASSEMBLY Cut out pattern for cam profile.S. and then along the profile of the cam at intervals as shown. Remove pattern and drill hole 3mm and then to size. bar 15 dia. Position pattern on a square corner of a piece of 1Omm plate and stick down with tape or clamp on. ‘\ pattern on page 2 Fig2 24 ..CAM 81LEVER ASSEMBLY PARTS Part !2 2 K5 K6 Name Cam Cam Cam Cam Cam Cam shell spacers spindle lever handle Quantity Dimensions (mm) 25 10 x 45 3 x x80 45M.S.flat plate 28 x 28 x 19 M. x 250 12 73 M. Grind off corners of nuts to make a smooth knob. Clamp tightly ralund and weld fFig. Mark out spacers K3 on a bar and drill to size. Bend the lever as shown. C#amp in vice and hammer shell round to fit the cam.30). Cut length of rod for lever K5 and find four nuts K6. Clamp the lever on to the cam and weld both sides. Then cut off. Weld spacers on to cam.Cut strip for cam shell K2. and weld the nuts on to the long end. Heat cam shell with a blow torch till red hot. Position as shown overlapping each side of the cam equally and parallel with the cam when viewed from the end. Cut spindles K4. Tack weld each side. 25 . Assemble spacers and cam on spindles centrally. or put in a forge SO that only the shell gets red. y :. .jl !.:z $:. .:/ Publications. ic. Reproduction of this microfiche document in any form is subject to the same restrictions as those of the original document.75. Ltd. .: of Intermediate Ltd. . :p.. :....A project of Volunteers in Asia AT MICROFICHE REFERENCE LIBRARY Machine for Sheet Metal Work How to Make a Folding by : Rob Hitchings Published by: Intermediate Technology 9 King Street London WCZE 8HN United Kingdom .. _....u: 4 Available from: Intermediate Technology 9 King Street London WC2E 8HN United Kingdom Reproduced Technology by permission Publications.. Publications. Paper copies are $ 3.d.. Ltd.. How to make a folding machine for sheet metal work Rob Hitchings . the machine could be btilt by most small metal workshops and blacksmiths. The ability to make locally. Designed specifically for construction from readily available steel sections. London WC2E 8HN.W. both in the developing countries and in the more industrialized nations. based in Cumbria (N. is being increasingly seen as very useful. it makes sense to encourag-.This manual. design and make village scale equipment for workshops both in the developing and industrialized countries. trays and agricultural equipment. Rob Hitchings is interested to hear from other designers/engineers who are building similar equipment around the world and hopes that a network of people may emerge who can share ideas and collaborate together to develop further designs. Intermediate Technology England. : :~4 self reliance and small-scale production of certain equipment. gives full details on how to build and use a versatile machine for working sheet metal. ISBN 0 90303I 76 0 . With the rising cost of fuel for transportation and growing awareness of the finite rescources of the planet. has a background in ‘practical’ engineering and appropriate technology workshops. How to make a folding machine for sheet metal work. It is equally useful for vehicle building and repair work. Publications Ltd. England).. * The clear illustrations and step-by-step building instructions make this a very practical manual for any small workshop wishing to increase its capacity to fabricate in sheet metal. Such a machine offers the increased facility of being able to readily produce items in sheet metal such as ducting. steel boxes. 9 King St. equipment for small farms and villages in rural areas. The Author (who also illustrated and layed out the pages for this manual).. His business (APT Design & Development). HOW TO MAKE A FOLDING MACHINE FOR SHEET METAL WORK Designed and written by Rob Hitchings Step-by-step instructions how to build a versatile machine for folding sheet Intermediate Technology Publications Ltd. . U. 2 . Nottingham. ISBN 0 993031 76 0 Printed by the Russell Press Ltd. 1981. Tapem to metal. 3p+---.----. @. Their assistance is gratefully acknowledged. \ Pattern for cam refer b page 24 Cut out square. Centre punch through pattern on dots at-d pivot centre. ! I I i I ! ! --.K.I 0 Intermediate Technology Publications 9 King Street. ‘2 ‘. ‘.Acknowledgements Financial assistance in the final development of this machine as well as in the production of this booklet was made available through Intermediate Technology Industrial Services from a grant from the Overseas Development Administration./. London WC2E 8HN Ltd.--. The only equipment essential to its construction is a drilling machine. angle and hollow steel sections using basic welding and fabrication techniques. baking-pans.The sheet metal folding machine. this machine will he found very useful in any small metal workshop to make objects in sheet metal such as boxes. troughs. the consiruction of which is described in detail in this bookfei. funnels. trays. air-ducts. chimney flues. as well as in the Third World. mechanical hacksaw and a ilame cutter would make it easier. in the . The machine can be bolted on to a strong bench or mounted on a stand. Construction can be modified to suit locally-available materials. This foiding machine should prove an invaluable tool in any small workshop industrialized countries. G clamps and basic hand tools. though these tools are not essential. It can be made from readily-available channul. or agricultural equipment such as seed-hoppers. An angle grinder. an electric cvelder. water and fuel tanks. Once constructed. is cheap to build and versatile in use. cabinets. channels. . Contents Page introduction Uses cf tne machine Description Detail drawings of machine components Construction Operation Optional designs 3 6 7 10 12 27 29 . ..: :. 5 .i ::.i’... structural work.5mm thick) x 1 metre wide and can produce both box sections. Box sections: air ducts. and pans up to 1OOmm deep (150mm on modified machine). Pans: boxes. water/fuel tanks. trays. troughs.&es’ of the folding ‘machine The machine will bend steel sheet up to 16 guage (approx. Several adaptations are suggested in the optional design section. Funnels: Grain/seed hoppers etc. Large boxes/tanks 6 . Some of the shapes and suggested items which this folding machine can produce are illustrated below. 1. chimneys. Once the basic machine has been built it can be adapted in numerous ways to do almost any sheet metal folding job (within the capacity of the machine’s strength). lids. This is not necessary for box sections (ducting). or for normal straight folds. The clamps slide from side to side to adjust to whatever width needed.___ the clamping beam. This has a handle which is raised and thus causes the clamped sheet metal to bend._. which clamps the sheet metal along the line that requires folding.The folding beam which is pivoted at each end.Description The machine comprises: .__ . Several clamping beams can be made to suit the widths of four-sided trays/pans required.The base frame assembly. clamp assemblies clamping beam base frame assembly -&g&g folding beam assemblyw Fig. which is suitably fixed down. . In such cases the full width beam can be used.Two clamp assemblies._. which act on . .1 . Note: All alphabetical letters on this and subsequent pages are also referred to in the detail drawings on pages 10 and 11. D2 The handle is of heavy iron pipe welded to the bottom side of the channel. Dl D2 Fig. and a piece of angle iron welded underneath to add rigidity. They also provide the pivot location for the folding beam. the clam:. C The mounting plates are heavy angle iron which serve to fix the machine down. A The fixed beam has a plate welded in each end. B The clamp slide serves to take downward pressure as the clamps are tightened. notched at each end to allow for the pivot pins. strip and two end plates. and comprises a piece of angle. It is also. slide. 8 D .3 FOLDING BEAM ASSEMBLY The folding beam is a plane piece of 100 x 50mm channel. This has recesses cut at each end for the pivot pins which are welded on Dl. and hold the fixed beam and clamp slide together. BASE FRAME ASSEMBLY This is made up of four separate fabrications: the fixed beam. and two mounting plates. but the simplest is to weld two pieces of angle together. 9 . H and K are designed for quick grip and release action. This is to allow the steel sheet to be bent further than 9o” so that it can spring back to a right angle. They are made from 50mm box section (square hollow section. As will he seen from the sectional drawing below they are offset. so called).CLAMPING ASSEMBLY The clamping beam F can be made in a number of ways. The fixed beam channel wants to turn but it is held firm by the side mounting plates. The result is that point Y puts pressure upwards on the back of the fixed beam channel. causing the clamp rocker to apply pressure to the top of the clamping beam. and point 2 puts pressure down on the clamp side. Fig. They operate as follows: The lever (K5) is pushed down and turns the cam.5 The clamp assemblies G. 60 I 60 50 I I1 1300 j-1 65 0 7 Cl 32 370 60 100 n M&F2 1220 Components D and D2 are drawn here Vi scale. all the other components are Vi scale. . 2. Dimensions in mm. ‘/ scale.P 7. .Gin 170 50 73 015 G446 so . 24 w H8- 90 H7: y” H8z O6 H8 cNFzra?lv 70 0 46 Kl mlo 46 K20 IO 60 i24 3 K3m 26 n2’ 19 K400 13 IS 01 12 K5 250 ‘~ ‘iK6 Detail Drawings of Machine Components Showing suggested side view and sections. Construction BASE FRAME ASSEMBLY PARTS Part Name Fixed beam Fixed beam end plates Fixed beam reinforcing angle Clamp slide Clamp cap Clamp slide end plates Pivot blocks Mounting plates Quantity Dimensions (mm) it1 A2 iI 82 El : 1 1 : . = Mild Steel) .S.S.S.flat angle (MS.S.S. M. flat 65 x 80 80 65 x 370 12 M. angle 60 25 x 60 5 x x1300 5 x 1300 M. flat angle 60 x60 x 5 M. channel 90 x 40 x 8 M. 100 x 50 x 1300 MS. M.S. flat SO x 60 x 1270 M.S. That means put short runs of welds (approx. File smooth. 25mm) at intervals of about Stlmm (in this case).7 Mark out and cut pivot recesses.BASE FRAME ASSEMBLY Cut channel A.-. - Fig. ‘Stitch weld’ .9 13 . 1 .Yt to see how this fits. Clamp in position just short of channel end and weld in place on inside only. Fid Cut angle AZ to fit in betieen end plates. angle B and flat 61 to length accurately and file ends square in all planes. Position carefully and ‘stitch weld’ in place. Cut end plates Al and file to fit inside channel. Study cross section tFig. Do not drill and tap yet Fig. CI. ..~ B *~~ ^_A wero ____1_1 eno prams sngnuy m nom me ena or me angle tlmm will do).1-a ye.pack the .... Weld front and top edges only.Mark out and cut clamp slide end plates (82) and file to fit inside angle B with flat Bl resting on top. ~. welding on the pivot blocks 14 .~L.10 plates C.Position . rod. .~^1 . s uo in not arm stitch welding the clamp slide Mark out accurately and cut the mounting holes with 3mm drill. on inside. with thin steel and clamp.. Stitch weld flat Bl on tca snare -. Note: Do not enlarge the holes yet. ano ma end ula. arru . cut out and clean up edges. Take a piece of 50 x SOmm square hollow section (the same as will be used for the clamp base HI and H2) to make sure that it will slide along between angle and. Fig.. Clamp to mounting plates and locate hole with piece of 3mm dia.flat B!.-‘.__I _.==.. . Drill hole 3mm. ‘. . Centre punch and drill all Mark out pivot blocks Cl.~ .1+. Clamp. Drill to all holes in mounting plates C. Note: Take care that the pivot hole is accurate and at right angles to the Fomting a~ plate.12 Tack weld in place if necessary in order to remove clamps for drilling.121. Leave assembled. Tap up the fixed beam gently with the hammer until this position is exact. and ensure that: -all ends are in position. and _a use . size -. for the ends of the fixed beam. (Sharpen first. -the top of the fixed beam is level with the underside of the flat Bl. Drill and tap holes in end plates Al and 82.most important . Remove all clamps. setting up the base frame before drilling Fig. Check now that the base frame assembly will bolt together properly. Break tack welds with chisel and clean off. Drill holes through into end plates Al and 82.Mark out on the end plates the positions the clamp slide. -the two mounting plates are in the same plane (look along them from one end as indicated). File holes out slightly only if necessary. and Set UP the base frame assembly using packing and clamps. speed and lubricant). 15 . _. .a 3mm drill inserted in the pivot hole lines up exactly with the corner of the fixed beam (Fig. then tighten clamps.slow _. Check e drill * * e mar you nave a prece or rouna oar ror me pivots me same srze as you are anrkng. S. Clamp in position and tack pins to 16 . Mark out . x SO M.and cut . It is best to cut on the short stde and file the prvot pin slightly as recesses for pivot pins Fig.S. dia.S.I~~d.W&lSNG BEAM ASSEMBLY - Part El D2 Name Folding beam Pivot pins Folding beam handle Quantity 1 l5 Dimensions (mm) 100 x 50 x 1299 M. tie folding beam is held in place.recess for pivot as inzI. = diameter See diagram on page 7 FOLDING BEAM ASSEMBLY Cut main channel D and file ends square.13 Cut the two pivot pins D and chamfer ends. File pivot pins until the two tops of the beams are level. and the front faces touch ‘gh. Position pins in holes in pivot blocks. and offer up the folding beam D. channel 20 dia. rod 25 nominal bore pipe M. Check that it fits easily between the mounting plates on the base assembly. If pipe-bending equipment is available the handle can be made as shown.15 Locate the handle centrally on the folding beam.the down tubes can be square section and the cross piece round. Fig.Unbolt one end mounting plate. Build up a good strong weld as this is a point of stress. Alternatively. (Make sure these are strong. Handle . and come to rest right up against the fixed beam. and weld in place. Grind welds and/or fixed beam to accommodate welds as necessary. the handle can be made up either by using some pre-bent tube already available or by welding up elbow pipe fittings. . Complete the welds holding the pivot pins. If not. Refit the folding beam into the base frame and ensure that it will rotate freely. especially at the outer ends of the folding beam). and remove the folding beam. CLAMPING ASSEMBLY sub-assemblies clamp rocker assembly cam and lever assembly clamp base assemblY clamping beam Fig.17 . Check that it is still straight.CLAMPING BEAM PARTS Part Fl F2 F3 Name Clamping beam top half rXafmping beam bottom Stop screw spacers Quantity : 2 Dimensions fmml 75 x 75 x 1220 M. angle as required F2 F3 Fl Fig. Put in vice or clamp to any sensible fixed object. angle 75 x 75 x 1220 M.S. Position off set and stitch weld as indicated.S.l! . and grind or file the leading edge p.Cut the two pieces of angle Fl and F2. and correct as required. filing the leading/folding edge Fig.lS F The clamping beam . !. bend and file a piece of 2mm plate to fit the front opening and weld in. with equal amounts protruding each side. Weld it in place from inside at the front.. Cut. ROCKER ASSEMBLY - Part El :: G4 :: G? GE Name Rocker body Rocker pivot Rocker top cap Rocker end cap Clamp foot Ca. MS. 2 ..S.S.S.20 CLAMP ROCKER ASSEMBLIES Remember to make two of each part whilst marking out and cutting.. plate pipe x 80 see drawing on page 11 4 see dia.S. O.dia. . drawing U. i_ ..:. The following describes the fabrication of one rocker.Zafollower Screws Return spring pin Quantitv - Dimensions (mm) . plate 46 piece x 46 of x27 4 M. x 60 approx M..‘.i.. rod $. 50 x 50 x x 73 170 M. on x 10 page 11 6 dia. Position centrally at tip of rocker and weld front and back. Cut a piece of water pipe and file to size shown. 20 . S.<. ‘yi.N. Rod box 80 x 45 x 2 M.C. Cut the pivot Gl and position through the rocker. Fig.LA. 2 : 2 15 dia. Cut the 60 x 5Omm square hollow section as shown and drill the holes for the pivot Gl. :. 21 Make up cam follower from 1. and drill and file elongated holes.5mm steel sheet. Cut piece of brass sheet G6 and wrap around 65. Note: This brass shim can be packed out with more brass or steel shim to increase the clamping pressure. I Fig.(Put screws G7 in whilst welding to avoid getting weld in the threads). .I Cut and file a piece of 3 _ 4mm plate to fit the back opening. and drill and tap as shown. Fit and weld. It is also easily replaced if wear occurs. flat 50 x 12 10 x 250 18 M.CLAMP BASE ASSEMBLY PARTS Part Hl E E H6 Ii. (A wood worker’s sash clama is aarticularlv useful for this). Ensure front edgs of H2 is a right angle. box 50 x 12 x 90 M.: Ii9 Name Clamp base column Clamp base foot Clamp base tongue Clamp base lip Rocker pivot supports Clamping beam stop screw Stop screw spacer Clamp base return spring pin Rocker return spring Quantity Dimensions (mm) 50 x 50 x 135 180 M.C.25 .S. x 7d approx Fig. flat flat 12 dia. x 90 6 10dia.S.24 CLAMP BASE ASSEMBLY Cut pieces Hl and H2.S.S. flat rod 10 dia. x 5 x 25 20 M.N. Clamp and weld. w - Fig. MS. U. Clamp one side to the base and position accurately as indicated. Shown here upside down. Remove assembly from the channel and weld foot on to base both sides. cut and drill pivot supports H5.2 6 Check that the clamped assembly will slide freely from side to side. Clamp H3 to H2. DO NOT WELD OTHER PIVOT SUPPORT ON YET.Cut H3 and H4. Clamp together and weld front and side edges. making sure of an extra strong weld at x Mark out accurately. Weld in place. Set the distance of the lip H4 from the column Hl by hooking on to the back edge of the channel A. I I Fig. 23 . bar 15 dia. M. . /-- \ Cam profileactual size ‘\ ..-. .-.S.CAM 81LEVER ASSEMBLY PARTS Part !2 2 K5 K6 Name Cam Cam Cam Cam Cam Cam shell spacers spindle lever handle Quantity Dimensions (mm) 25 10 x 45 3 x x80 45M.S.S.S. ‘\ pattern on page 2 Fig2 24 . M. Finish with a file and check for squareness all roun . Cut profile over size and grind almost to line of dots.rod rod 12 threaded nut Fig. Centre punch the centre of the cam pivot.S. Remove pattern and drill hole 3mm and then to size. x 250 12 73 M.28 CAM ASSEMBLY Cut out pattern for cam profile.flat plate 28 x 28 x 19 M. and then along the profile of the cam at intervals as shown.. Position pattern on a square corner of a piece of 1Omm plate and stick down with tape or clamp on. C#amp in vice and hammer shell round to fit the cam. and weld the nuts on to the long end. Heat cam shell with a blow torch till red hot. Weld spacers on to cam. Clamp the lever on to the cam and weld both sides. Mark out spacers K3 on a bar and drill to size.30). Cut spindles K4. Then cut off. Grind off corners of nuts to make a smooth knob. Clamp tightly ralund and weld fFig. Cut length of rod for lever K5 and find four nuts K6.Cut strip for cam shell K2. or put in a forge SO that only the shell gets red. Bend the lever as shown. Tack weld each side. Assemble spacers and cam on spindles centrally. 25 . Position as shown overlapping each side of the cam equally and parallel with the cam when viewed from the end. The machine is now ready for use. With a slight twist the clamp assemblies can be hooked on to the back of the fixed beam.ASSEMBLY OF CLAMP Fit the rocker and the cam on to the pivot support H5 which is already welded to the column. Fit on other pivot support and clamp ready for welding. 26 . insert a thin piece of sheet metal (e.g. The folding beam and the clamp slide can now be fitted.34 FINAL ASSEMBLY Remove the clamp slide from the base frame. piece of tin can) between the pivot suppo> and the clamp column and foot. Check that the cam and the rocker are free to pivot. (Grease all pivo:s and holes first). If not. When satisfied that the cam and rocker are working freely. piece of tin car Fia. weld as indicated.3: I Fig. welding spacer on to stop screw shim (e.g. (and check that the cam does not foul the column). tack weld to clamping Mark out sheet metal to be folded. until the line is just in front of the folding edge. Place the clamping beam on top of the fixed beam and under the clamps.~ where the adjusting screws are to operate. (Ideally a heavy bench or one which is fixed down).35 How to fold a pan A special purpose clamping beam will have to be made up for each size of pan you require to make. flaps if required for riveting. Insert the sheet between clamping and fixed beam. At this point it may be necessary to fit spacers F3 on the back of the clamping ~YZYZ. decide the dimensions for your pan. 27 . and mark out on the sheet metal to be used. (This can be adjusted according to the thickness of sheet metal being folded. Push clamp handles down. Bearing this in mind. Raise folding beam handle till requrred bend is achieved. Felt tip (spirit ink) pens are ideal for galvanized sheet.Operation Clamp or boit the base to a suitable bench top. If so. Line up the folding edge about lmm back from the crack between the fixed beam and the folding beam. brazing or soldering ----- Fig. and the tightness or corner required). Side P can now be inserted between the special length clamping beam and the fixed beam. angle iron on bench edge). fnldinn the nffat in nne f&j ------ I iT-- tackwe. with a strip of sheet metal tacked in place as shown. the folding machine can be adapted to put the offset on the tongues in one go. and they need tongues on the corners.d L ~~~ offset 4 g Fig. strip of sheet metal yidth of Q . and the box/pan bent up as far as it wiH go. Finish off the bend with a hammer. preferably over a hard edae.g.31 v Slacken off the adjusting screws to line up the front of strip R about lmm behind the front edge of the fixed beam.For a single pan The sides with the flats on the same fold line must be bent first (side Q). The result will be the offset required. Bend P as before. This can be done as described on page 27. Tack weld strips of metal as indicated. 28 . A clamping beam the width of P must now be made or adapted. Put the base of the box/pan right under the clamping beam and fold up the end Q. An absolute right angle cannot be achieved as the sides Q prevent this. The flaps must now be hammered slightly on a sharp metal corner (e. hammer here For a number of pans the same size If many boxes/pans the same size are required. and take care to line them up with the sheet being bent. 4 titch weld the bottom angle to the flat.e.Optional designs Folding beam If it is required to bend return folds as shown. taking care to avoid aistortion (i. it will be found that the folds cannoi be made any closer together than the width of the folding beam (i. but the angle can be removed to do close return bends in light guage metal. 29 . This folding beam can be used as normal. the following 10. sills etc.15mm steel flat x 75mm (preferably bright alternative Fig. 50mm).e. This set-up is ideal for car booy work. 5omm~ In order to do closer return folds. eld inside and outside at same piace alternately and put more welds on the outside rather than the other way round).?2 folding beam can be 15Am improved folding beam for tighter return bends V Fig. 41 Fis. the clamp system can be re-designed perhaps along lines similar to this. if even greater depth is required. ducting etc. Fig.42 Alternatively.To bend deeper pans The design detailed in this book will only accommodate pans/trays of aeprh up to IOOmm. -With fabrication of 10 x 50mm flat (Fig. 30 .42). To increase this capacity up to 150mm the clamps can be constructed as follows: -With clamp pivot plates cut from solid 1Omm plate fFig. Shaft and l&k ::I: ~~~~~~ n use with 3 Clamping beam for nc!mal use &Eeg straight folds.41). removable spacing block I Fig. the clamping beam can be made auiomatically self raising when ihe ciamps are released.47 Funnels If it is required to fold funnels with a small hole at one end. The springs H9 pull the clamp rocker down at the back and so raise the clamping beam up at the front. Remember to make one end removable so the funnel can be slid off.46).Self raising clamping beam In order to make it easier to slide in the sheet metal to be bent. L Fig. to locate on the clamp foot G4. .45 izn . Two small hooks can be welded on to the top of the clamping beam at each end. hooks Fig. a clamping beam as shown will handle thin sheet quite well. using a similar fabrication as shown fFig.=.-dc Folds greater than 90° Special clamping beams can be made to enable folds to be made up to 135”. .44 Bending radius curves on sheet metal Special clamping beams can be made up to fold curved corners I as illustrated.
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