[TheForge] Re:half-round with a hard right angle bend

[Tom Troszak]

If I needed a 3/4 wide half-round profile square frame with a solid right 
angle corners and all I had was 3/4 round to work with I would do it like 
this:

1. draw out both ends and three middle sections of a piece of 3/4 rnd to 
approx 5/8 dia, leaving four full 3/4" dia round sections (say at least 2" 
long) for each corner.

2. profile the 5/8 ends and three 5/8" dia middle sections in the 3/4 half 
round on the swage block up to the edge of the middle blob keeping them in 
the same plane.

3. heat each of the 3/4"dia blobs in turn to bright yellow and make a sharp 
right angle inside bend then use a straight peen hammer diagonally across 
the corner (lay the corner out flat way now) of the bent 3/4 dia blob to 
draw (push) material out to a sharp outer corner being careful not to make 
it too thin at the edge.

4, use the swage block to profile (SMASH) the remaining thick sections of 
the new corner as close as you can get to the crook then simply file the 
rest of the profile into the crook of the corner where you can't reach with 
the swage.

you can do all four corners this way by leaving bosses at appropriate 
intervals for the size of the frame, then make a simple lap joint in the 
straight section where it is easy to hide...if you dont have a welder, file 
a lap joint (very flat, about 1" of lap) through the straight part the flat 
way, then carefully drill  and fit a Coutersunk (both sides) rivet through 
the middle of the lap, then hammer or file the rivet head flush with the 
profile, it must be countersunk deeply or it will have no head when you are 
done filing. you can flux and soft solder the lap if you want.. or just 
leave it riveted. just don't try to make a joint in the corners.

hope this is helpful, I can draw a picture if necessary

Tom Troszak



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