How to Bend & Shape Aluminum

Many types of siding are made from aluminum.

Aluminum and other sheet metals can be bent and shaped over bases made of wood. Hammering forms the metal to the shape of the wood, and hammering against a wood plank will prevent damage to the aluminum sheeting. It should be noted that the bends created in the aluminum will be at slightly less of an angle than the wooden base. Harder metals such as steel might require the bases be reinforced with metal, but aluminum can be bent using only a wood base.

Things You'll Need

• Scrap lumber
• 2 C-clamps
• Saw
• 1-inch-by-4-inch plank
• Hammer

Instructions

1. Cut angles out of wood to match each bend. Two-by-fours of lumber work well for this task, although scrap lumber will work, as well.

2. Secure the lumber to the table with C-clamps or a vice.

3. Lay the aluminum over the wood, and hold it in place with your hands.

4. Place a 1-inch-by-4-inch plank 3 to 4 inches long on top of the aluminum where it meets the wood underneath.

5. Hammer against the plank, moving it along the wood underneath and bending the aluminum to match the shape of the wood.

6. Reposition the aluminum for the next bend, and continue the process until the entire form is shaped.

References

• Bend Works: The Fine Art of Sheet Metal Bending
• Custom Part: Sheet Metal Forming