[TheForge] using a pan & box hand brake.

[GRAF]

terry,
The fold around is hammer and stake work.
Mike Graf

terry l. ridder wrote:
> hello;
>
> a generous individual has sent me a late christmas
> present, a grizzly pan & box hand brake. words alone
> do not express my thankfulness to this individual. this has been a 
> great help in improving my outlook
> on life in general.
>
> http://www.grizzly.com/products/12-Box-and-Pan-Brake/G0556
>
> right now it is temporarily mounted to a wood stand. later
> i plan on mounting it to a large 3 ft section of log so it
> will be close to the height i need when in the wheelchair.
>
> before i start bending metal and making scrap metal ;-)
> i have been using heavy construction paper or thin cardboard
> to work through the necessary steps to make the pan or box.
>
> i have been using aluminum flashing, old aluminum flashing,
> and 28 gauge bare sheet metal to get a clear and concise
> handle on using it. i have down the simple welded corners
> pans and boxes.
>
>     +-----------------------+
>     |                       |
> +--+--.--.--.--.--.--.--.--+--+
> |  l                       l  |
> |  .                       .  |
> |  l                       l  |
> |  .                       .  |
> +--+--.--.--.--.--.--.--.--+--+
>     |                       |
>     +-----------------------+
>
> fold line => --.--
> fold line => l.l.
>
> what is giving me problems is forming a folded corner
> pan or box. here is what i am currently doing and
> where i am having the problem.
>
> 0. take a piece of aluminum the size of a sheet of
>     computer paper.
> 1. mark off 1/4 inch hem all around the edge.
> 2. mark off the pan sides from the hem edge.
> 3. mark off from each corner 1/2 inch and draw a line
>     connecting the two 1/2 inch marks.
>     http://maria-enzersdorf.blauedonau.com/pan-and-box-layout-small.jpg
> 4. using tinsnips snip off the small triangle at each
>     corner.
>     http://maria-enzersdorf.blauedonau.com/pan-and-box-hem-small.jpg
> 5. fold over the long side hems and hammer down flat.
> 6. fold over the short side hems and hammer down flat.
> 7. using a chisel and mallet gently place a crease on a
>     45 degree angle at each corner
>     http://maria-enzersdorf.blauedonau.com/pan-and-box-small.jpg
>
> okay at this point i have tried bending the short side
> first then the long side and the long side first then
> the short side. either way i am not getting the folded
> corner to form correctly. the folded corner should end
> up against the short side.
>
> any hints, suggestions, comments are most welcomed.
> any suggestions as to a good book preferably available
> via lindsay books on the care, feeding, and use of a
> pan and box handbrake would also be most appreciated.
>