Work In Progress - Mini 1' Folder

[bluebanana32]

Hi all, this was my weekend project.
I've wanted a small heavy duty metal folder for a while. As you have probably seen I made a 30 ton hydraulic one last year, but it is not great for tight angles less than 90 Deg. I have considered buying one but most can only bend around 1mm
I have recently been looking at 'welderpaul's' but I wanted one you could box sides as well. The only problem is money...!
So I went through the scrap bin and made this out of some off cuts and an old over engineered gate latch.
It's not quite finished, as it needs mounting to a bench and painting. Also I have some ideas for some different tooling options which can replace the 40x10mm bars.

 

[bluebanana32]

Finished and Mounted to the Bench

Well, today finally finished it, ready for painting.
It really easily bends thin steel like 1.5mm.
2.5mm Mild Steel can be done with one hand.
3mm is a little harder, but still doesn't need the extension arms fitted.
I have video'd it working, bending a piece of 3mm sheet, which you can watch on you tube.
http://youtu.be/C5Z_272Qn5s

I have included a spectacularly bad picture of box folded 2.5mm mild steel and 2x 3mm bend pictures, I literally wanted to see how it handled. Obviously with more time, care and accurate cutting you would have a much nicer finish.

I'm now using it for a job for the first time to make a customer a bespoke ash pan for there wood burner, so it can start paying for itself.

 

[Exuptoy]

Nice job!

 

[bluebanana32]

Thanks Exuptoy

 

[Exuptoy]

No probs. couldn't quite work it out till I checked out the vid. You could make some infill blanks of various sizes to swap out all those fillers to save moving them about too much.

I just have a machine mart 24 inch folder which does hat I need at the moment. I like the idea though.

 

[bluebanana32]

Good idea. I had plans to make another full length box section bar to replace the 40x10's for quick folds, but your idea would be more versatile. cheers

 

[hotrodder]

You could just tack the 10mm bars together to make different size fingers i.e. less fidly to adjust but can still make up pretty much any length. A one piece bar is still a good idea as if the fingers aren't all set exactly it shows when bending thinner sheet- another way if there's enough set back adjustment is to fold something tight over the fingers and leave it in place for straight bends. I'm usually working with ally so the increase in bend radius is a bonus as most box and pans are designed more around sharp/crisp bends in thin steel

 

[bluebanana32]

There is approx 15mm of back adjustment, so that would be a possibility. I am leaning more towards a 10mm v edged bar with box section welded above, cut into 3 or 4 variable lengths for thinner material (Sharp Edges) and tacking is a good idea for the thicker stuff.

 

[bluebanana32]

All Painted Up

 

[robwizard]

Looks really good!

 

[bluebanana32]

Thin Metal Tooling

So today I have been making the thin metal tooling.
These inserts will bend upto 2mm approx.

 

[Exuptoy]

Looking real nice. Good to see my suggestion being taken of a number of different inserts being made.
Well done on a quality looking bit of kit.

You must have some scrap bin!

 

[bluebanana32]

You must have some scrap bin!

Thanks, one single garage full of crap ( I mean treasure)

 

[bluebanana32]

My first commission using the new folder...

So I was asked by a customer recently to fabricate a custom ash pan for her pot belly stove.
So here it is.
It was folded using the thin metal tools, the M/S in 1.6mm thick.
(I know 1.6mm is overkill, but my steel supplier is out of thinner stock, at least it will last a long time )
I think it has worked quite well really, I have never used a professional box pan folder, so its difficult to compare the folds, but it's good enough for me.

 

[Exuptoy]

Nice work!

 

[gerrymoore]

Hiya Bluebanana...that folder is just what I'm looking for!! I need to bend some 2mm x 30cm wide mild steel...although 1.5mm would probably do me. I can work out how you've made it apart from the hinges!! Don't suppose you have any drawn plans at all? ...or any close ups of the hinge parts? Thanks Gerry

 

[julianthegypsy]

Nice work! The ashpan certainly looks up to scratch, and in 1.5mm will probably outlast the potbelly stove!

 

[bluebanana32]

Basic Hinge Plans

Hiya Bluebanana...that folder is just what I'm looking for!! I need to bend some 2mm x 30cm wide mild steel...although 1.5mm would probably do me. I can work out how you've made it apart from the hinges!! Don't suppose you have any drawn plans at all? ...or any close ups of the hinge parts? Thanks Gerry

I have attached a few piccies of the hinge assembly, hope this helps.

The line that is missing txt is for the folder base which is 10mm m/s plate, there is about 1 mm gap between the folding bar and folder base.

 

[gerrymoore]

Thanks for the info...it should help a lot!!