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

Thu Apr 24 21:34:00 2003

Tom -

Thanks for the response.
I agree with most of this, though I think I'd consider making an anvil tool for
the corners by bending a section of 3/4" round and hammering the profile into a
hunk of steel. I'd then use that for swaging the corners (as has already been
suggested).

Sorry it took a short while to reply, but I'd saved this to read later when I
could properly digest it.

Consider it digested.

All the best,

Bob

-----Original Message-----
From: [email protected]
[mailto:[email protected]]On Behalf Of Tom Troszak
Sent: Wednesday, April 23, 2003 12:26 AM
To: [email protected]
Subject: [TheForge] Re:half-round with a hard right angle bend

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

_________________________________________________________________
MSN 8 helps eliminate e-mail viruses. Get 2 months FREE*.
http://join.msn.com/?page=features/virus

_______________________________________________
http://mailman.qth.net/mailman/listinfo/theforge
theforge mail list group photo site is
http://www.photoaccess.com
Login:  [email protected]
password:  anvil
___________