If you roll the box hot it won’t crack or buckle.
You will always get rippling though on the compression side.
cover with filler.
paint.
I hope you mean load bearing paint....
@fizzy Have you considered searching around and finding something already bent and formed, like old school work tables, desks etc which you could adapt....in fact, 'upcycle'.....
cut the sides and bottom of the tube off where the bend is.
form the bend in the top "side"
fill with expanding foam.
cover with filler.
paint.
or is that just chassis repairs on transit vans.
i have no sensible suggestions beyond what has already been said.
i'd use the "cut slots, bend, weld" method personally.
best pic i could find:
View attachment 188696
Youd end up squashing the box when you put pressure on it i'd think. It will end up 100x10 box around the rolled bits.The problem the compression has to be lost somewhere you wont get the smooth radius
I like the way that made that into a feature!
I did think of this method but it needs to be smooth on the inside as lots of cables will be fed through.
@fizzy
My local steel stockist had bends like that waiting for a customer collection.
Each bend had a 50mm tang to allow it to slide inside the box section of the frame.
You may want to investigate that approach.
I make my radius corners by cutting up tube the right size and welding it in. Makes the table easier to build too.
View attachment 188766 View attachment 188767 View attachment 188768 View attachment 188769
Only problem is my brother wants rectangular tube that is fairly wide in relation to height