Radius Edge Tool?

[Mark]

Hi folks,

I have reached the stage where I need to fabricate a dashboard for my P4. I will be making this out of aluminium sheet.

Does anyone know if there is a tool available for the DIYer that will allow me to form a neat radius on the edge of the sheet? Here is a pic of the part I need to make up.

Any ideas greatly appreciated.

 

[Randy V]

I would make a wooden Buck with the contour of the panel that I wanted - clamp the metal to it and slowly work it with a large steel roller and hammer around the edges.. Try it on a small practice piece first to get the hang on it and to ensure the metal you've selected is malleable enough to be worked...

Eglitom has done something similar on his RCR for the front splash shields.

 

[Andy Green]

Hi Mark,
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As Randy said. If it’s relatively thin aluminum (1 – 1.5mm) I’d copy the profile onto a piece of hardwood or MDF and then use a router to cut a radius onto the edge. Clamp the ally to your new former and then hammer forming the edge of the sheet to match the new radius.<o></o>
It would be worth annealing the ally first to aid the process.<o></o>
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Hope this helps<o></o>
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Regards<o></o>
Andy<o></o>

 

[Jack]

Make a wooden former to exact shape. Clamp the aluminum in place (roughly trimmed).

Should you decide to anneal the aluminum, use a carbonizing flame all around.

Use a WOODEN tool to beat the aluminum into shape. This prevents marring and scratching. Shape a hardwood 2x4 if needed.

 

[Mark]

Good ideas guys, thanks for the tips. I'll let you know how I get on.

Mark