Normally I would have just bought some aluminum boxes but the prices are ridiculous, and I did not have a finger break to make my own. Having no real metal brake, I had to improvise. and the results were better than I had hoped for. So here is what we did:
Requirements:
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| figure 1. First bends |
| figure 2. After clean up. |
- 3 pieces of square steel tubing 2 of them about 1 foot, the other maybe about 2 feet.
- Optional 2 1/2"x20 blots about 3" long and nuts.
- Large deep through vice.
- Muscle
- Demel with an abrasive disk.
- Dead Blow Hammer
- So mark your metal mine is .004 sheet aluminum.
- Align and clamp between the two shorter tubing.
- You could drill two holes one at each end for nuts and bolts 1/2" x 20 or bigger hardware tack the nuts in place align and tighten.
- place in vice long end up and tighten.
- Using longer tube push on the aluminum plate at the bottom. (hence the term gorilla) (fig 1)
- Then to complete your bend to square it using a Dremel with an abrasive disk to score it on the bend line. (if I had done this step before the bend there would have been less bow and the angles would be closer to 90 degrees.
- Then clean up with dead blow hammer on square tubing.