- Joined
- Oct 31, 2014
- Messages
- 444
Hi all,
Current project is to make some 18" x 24" rectangular 'picture frames' or "shadow boxes" out of 3/4" x 3/4" x 0.0625" T6063 aluminum angle.
My first pass, trying to do it with one continuous piece of stock: Cut angle to length (84 inches) and then notch out 90 degrees at 18" and 24" corner locations, then bend the corners on the finger brake to form a rectangle, then TIG the corners and voila! - a frame.
Well, not quite. When I bend the corners at the miter locations the notches close up before I get to 90 degrees - more like 80 degree angles. The thickness of the material makes the bend radius a bit wonky. So I tried double notching the material, making the notch a bit wider to compensate for the thickness of the stock. That sorta worked but I couldn't repeat the notch width reliably nor figure out where to start each bend relative to the notch to get it to be 18 x 24 accurately. I am also having trouble cutting the two ends properly square so they fitup well for welding. Tinsnips work but it's like the ends are gnawed rather than cut.
So, question 1: What am I doing wrong?
Question 2: Would it be better ( i.e. less crazy-making) to angle / miter saw the material (6063 is pretty gummy) into 4 pieces and weld instead of the described one-piece method? If so, what sort of saw / blade combination would work?
I realize, in reading the above, that I should add some pictures as it is not really clear from my description what I want to do or what's going wrong. It's late and I'll post this and see what happens, then add some photos tomorrow once the questions start.
Thank you and Good night !
Stu
Current project is to make some 18" x 24" rectangular 'picture frames' or "shadow boxes" out of 3/4" x 3/4" x 0.0625" T6063 aluminum angle.
My first pass, trying to do it with one continuous piece of stock: Cut angle to length (84 inches) and then notch out 90 degrees at 18" and 24" corner locations, then bend the corners on the finger brake to form a rectangle, then TIG the corners and voila! - a frame.
Well, not quite. When I bend the corners at the miter locations the notches close up before I get to 90 degrees - more like 80 degree angles. The thickness of the material makes the bend radius a bit wonky. So I tried double notching the material, making the notch a bit wider to compensate for the thickness of the stock. That sorta worked but I couldn't repeat the notch width reliably nor figure out where to start each bend relative to the notch to get it to be 18 x 24 accurately. I am also having trouble cutting the two ends properly square so they fitup well for welding. Tinsnips work but it's like the ends are gnawed rather than cut.
So, question 1: What am I doing wrong?
Question 2: Would it be better ( i.e. less crazy-making) to angle / miter saw the material (6063 is pretty gummy) into 4 pieces and weld instead of the described one-piece method? If so, what sort of saw / blade combination would work?
I realize, in reading the above, that I should add some pictures as it is not really clear from my description what I want to do or what's going wrong. It's late and I'll post this and see what happens, then add some photos tomorrow once the questions start.
Thank you and Good night !
Stu