bending jig for top covers?

[deknow]

Hi all,

Getting ready to make some top covers, and I want to do a neat job of bending the metal pans (neat corners, no sharp edges).

I've got a few ideas, but want to benefit from the blunders of others...I prefer to make original blunders where possible!

deknow

[Barry]

Get yourself one of these:

http://t2.gstatic.com/images?q=tbn:A...FqjRxWuxx_e-P5

For the long bends, any sharp edge you can bend over works fine unless you're using some really heavy gauge material.

[deknow]

...not looking to bend anything very heavy duty, but since they are all going to be the same, i'd like to put together a jig or system that does exactly what i want it to do without measuring each bend.
that's a good start, but not really what i'm after...thanks.

deknow

[BeeCurious]

One thing I found to be helpful is to score the aluminum with a cutter before starting the bend.

[Barry]

since they are all going to be the same, i'd like to put together a jig

Unless you have a sheet metal shop, you're going to have to do a fair amount of hand work. You can easily make a jig for the layout. Cut a piece of plywood that has a rectangle cut out of it the size of lid and is 1-1/2" "frame". Lay it on top of the piece of metal and trace the bend lines on the inside and the cut lines on the outside. Beyond that It's all hand work.

Here is a bend/cut diagram. Solid lines are cuts, dash are bends.

[Riskybizz]

Deknow,

After reading some of the posts on here regarding making and installing metal covers for telescoping tops I called my local paper the Santa Fe New Mexican and asked if they had any used printing plates as discussed by some in the forums. Sure they said how many would you like? So I drove down there and they had piles of them neatly stacked in two different sizes. The price is the same for each he said we get $1.00 each. They are used aluminum printing plates. They also recycle them back to the supplier at the same price. The plates cleaned up very easy with a damp cloth and I proceeded to make one for a new telescoping top. I measured the top and layed out the dimensions on the plate and cut it with a pair of scizzors (no need to use metal shears) they cut easily. I allowed for a 1" overhang onto the sides of the top coers and simply layed a metal framing square on the line and bent it up with a hive tool working my way all the way down. You do not need any special tools to make the bend, just a flat straight edge will work fine. The bend created a very nice sharp crease. I was amazed at how easy they were to make up. If all your telescoping tops are the same size I suppose you could cut all the aluminum sheets the same but in my case I measure each one as the size does vary slightly and I wanted mine to fit tight. I will take a picture if you'd like to show you how mine came out. I like the aluminum as opposed to the heavy galvanized sheets as they are so easy to work with. One word of caution, after you cut the sheets use sandpaper or a fine file to take the edge off the sheet, as they are very sharp. Once you nail them to the top covers your good to go. You can also read the old news when your in the bee yards. Good luck.

[jrbbees]

At Lowes you can buy rolls of alum. flashing in 10 ft or 50 rolls. The 20 inch wide flashing does well with the bender shown above in the 2nd post.

Just be careful when you unwrap the roll at it will want to unroll real fast.

[dixiebooks]

FWIW, just today I picked up 50 sheets of aluminum from my local paper. They're much too narrow to use on regular hive covers. Maybe I'll make some for nucs. BTW, they charged me .33 each for them.

-james

[Acebird]

...not looking to bend anything very heavy duty, but since they are all going to be the same, i'd like to put together a jig or system that does exactly what i want it to do without measuring each bend.
that's a good start, but not really what i'm after...thanks.

deknow

A door jam makes a good break for thin metal. You will have to cut slots in the door for the two sides that are previously bent. If you are going to make this jig use a couple of heavy hinges and a hardwood board as the break edge. You can put whatever radii you want if you don't want a sharp bend.

[whix]

I also use old aluminum printing plates. I can get two lids from one plate at a cost of 50¢ each lid. I score the plate ONCE with a box knife and bend over on the score. The metal will tear on the score. Rub the cut with a piece of hardwood to remove the burr or you will filet your fingers. (don't ask how I know).
I made a bending jig from a piece of hardwood a little longer than the longest side. I made a thin kerf cut along one side to the depth of the fold. I also cut off a 45 degree angle along one side (just cut off half of one of the corners). This cut allows you to fold more than 90 degrees.
Cut the plate to the size of your lid and the folds, I have a scrap piece of plate cut the depth of the fold that I use to centre the lid on the metal on all sides. That way I don't have to measure. Put the plate to the bottom of the cut and fold over in the direction of the 45 degree cut. The plate bends very easily. I do the long sides first and then flatten one fold with my thumb to get the metal in the jig for the short side, the other end sticks out. I only do three sides with the jig, although if you are accurate enough with the cutting and have a uniform lid size you could do all four sides. The last side is folded over by hand as I install it on the lid. Tap with a hammer to fold over the corners and nail it on.
A word of advice, put the image side to the outside of the lid. The shiny side will make you go blind in the sun.

[Jack Grimshaw]

Dean,
Befriend a roofer or someone who does siding.Ask if they have a trim brake.
Maybe someone in your club.
Precut your pieces per Barry's diagram.
Case of honey for 2 hrs of their time?
I personally use my fingers and then gently tap with a hammer and a wood block. The bees don't care.

[Alexander]

I believe Whixen was talking about making a bar folder. You could make one out of metal or wood. Just something with a slit in it as deep as the bend is from the edge of the metal. Or you could buy a bar folder 18" or 24" long to bend the whole side at once. Or better yet make two that are each the same length as the sides on your hive top.

[Barry]

A hand seamer can be made easily as well. Take two pieces of steel flat stock (1/16" thick), bolt the two together inserting a washer between the two to create a gap. Use as many bolts as necessary to keep together. Make a seamer/break for each dimension, that way you can bend them all in one shot. Make it wide enough so the distance from the long edge to the center bolt is the same as the width of the material needed to be bent.

[beedeetee]

I use the 20" flashing from Lowes and I made a sheet metal brake from plans that I found on the internet somewhere. It is made from 2x4's.

Or look here:

http://www.beesource.com/forums/showthread.php?t=249611

[Roland]

We have a home made bar fold that was made in the 40's from a wood base, two pieces of 2x2 ,a couple hinges, and two lengths of angle iron to reinforce the bending edge. The base has two nuts embeded in it, and two bolts where converted to cranks to clamp the material under a 2x2. The hinges are inset on the edge, past the width of the roof, and pivot the last 2x2. A short piece of pipe in a hole drilled in the bending 2x2 gives leverage. It is not pretty, but functions.

So yes, it ends up looking like a door in a way.
Crazy Roland

[David LaFerney]

Make the saw kerf how ever deep you want the bend to be - no more measuring.

[Jack Grimshaw]

Sweet!!!

[David LaFerney]

Sweet!!!

Pretty hard to beat for simple yet effective.

[Dave W]

Who says the "wheel" cant be reinvented?

We now have the LaFerney Brake!

VERY sweet

[Michael B]

I am going to try the 2x4 brake wery soon. What a beautiful idea.