How to Roll Aluminum Strips Into a Channel
Aluminum, also known as aluminium, is a soft, silver-white metal. It is lightweight, highly reflective, corrosion resistant, as well as thermally and electrically conductive. It is the most abundant metallic element on Earth. Because of these factors, aluminum is the second most used metal after steel and a common material used for channels. There are three types of channels most often used -- U-shaped channels, C-channels and J-shaped channels. Does this Spark an idea?
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Things You'll Need
- Aluminum sheet metal strips
- Hand bending brake
- Marker
- Measuring tape
- Straight edge
- Work table
- Work gloves
Instructions
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Select your aluminum specifications. Channels can be made from a variety of thicknesses of aluminum, depending on the final application; however, most commonly the thickness doesn't exceed 1/4-inch. Additionally, aluminum is available in different hardnesses. Select a thickness and hardness appropriate for the project where the channel will be used.
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Select a U-shaped, C-shaped or J-shaped design. A U-shaped design features two, upright sides of equal length, connected to the bottom of the channel. A C-shaped design also features two, upright sides of equal length; however, the sides are shorter than the width of the bottom of the channel. A J-shaped design features two, upright sides as well, with one of the sides significantly shorter than the other, connected to the bottom of the channel. Your channel can be designed to any dimensions. With your final application in mind, determine the side heights of your channel, as well as the width of the bottom of your channel.
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Mark the heights and width from your design onto the aluminum. Use the straight edge to draw the bend line of your design, as well as make an indication as to the direction of the bend. You do not want to bend the aluminum the wrong way, as having to re-bend it will significantly weaken that area.
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Place the strip of aluminum in the hand brake, aligning the bend line you've made with the break in the hand brake. Following the hand brake manufacturer's instructions, lock the hand brake into place, securing the top of the metal. Pull the hand brake lever forward to engage the hand brake and bend the aluminum. When the aluminum is bent to a 90-degree angle, release the lever and unlock the machine to release the aluminum strip. Reposition the aluminum for the second bend, and repeat.
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Tips & Warnings
Practice on scrap pieces of aluminum to ensure you're familiar with the use of the hand brake and with forming a 90-degree angle.
Always wear protective gloves when working with sheet metal of any kind.
Edges of the aluminum strip may be extremely sharp
References
Resources
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