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How to Make a Sheet Metal Folder

A sheet metal folder, also known as a sheet metal brake, is an essential addition to the shop of any metal worker. Formed metal is used for many applications, from auto body repairs to HVAC installation and a wide range of projects in between. The dimensions and strength of the parts used to build the metal folder will depend upon the size and gauge of the metal to be formed. Metal folders, no matter the size, are all based on the same principals: a clamping assembly and a bending mechanism. These can range from simple to elaborate.

Things You'll Need

2 3-inch pieces of 3/16 by 1.25-inch wide flat stock of iron
2 1.25-inch pieces of 3/16 by 1.25-inch wide flat stock of iron
2 2.625-inch pieces of 3/16 by 1.25-inch wide flat stock of iron
2 inches of 5/8-inch round bar
2 25-inch pieces of 2-by-2-by-3/16-inch angle iron
2 3.5-inch pieces of 2-by-2 by-3/16-angle iron
2 23-inch pieces of 1-by-1 by-¼ inch angle iron
2 feet of 1.75-by-1.75-by-1/8-inch angle iron
2 10-inch pieces of ¾-inch 16-gauge tubing
2 bolts, ¾-by-2 inch
2 matching nuts
2 matching rubber handles
Welder
Welding helmet
Safety goggles
Grinder with cut off wheel
Drill
Clamps
Tape measure
File

Instructions

- 1
  Drill a centered hole, ½ inch from the end of both the 1¼-inch-by-1¼-inch pieces of flat stock and both of the 2.625-inch sections. Grind the end of both 2.625-inch sections where the hole is, leaving 3/16 inch of metal remaining and ½ inch in the center. The ½ inch from the ends leaves room for sections to be welded. Measure all parts carefully before drilling or grinding to avoid lost time and unusable pieces.
- 2
  Smooth away any rough edges left by the drill or grinder with a small file. Weld the 1¼-inch square to the 3-inch piece of metal, overlapping the edges by only ¼-inch before welding. Repeat with the second 1¼-inch square and the second 3-inch piece.
- 3
  Align the holes of the 1¼-inch square and the 2.625-inch piece. Grind extra metal away if needed to make pieces line up. Place 5/8-inch pieces of round bar into the holes, rotating to insure proper mobility of your hinges. Bevel one end of each rod and push through both holes until flush with the 1¼-inch square. Check for proper rotation and make any adjustments necessary. Weld together, filling in where the rod is beveled. Grind excess round bar that is protruding from the other side of the hinge.
- 4
  Clamp two pieces of 25-inch 2-by-2-by-3/16 inch angle iron together and center with the 5/8-inch rod and weld to each hinge. The positioning of the hinges is tricky. Measure carefully to ensure that all pieces are centered before welding.
- 5
  Remove the head from both bolts and cut them in half lengthways, about half way up the bolt, leaving an L-shaped bolt. Weld to the side of the hinge that does not have the rod welded to it. Construct the base to attach the metal folder to the table by welding two 3½-inch long pieces of 2-by-2-by-3/16 inch angle iron to the bottom of the hinges.
- 6
  Clamp together the bracing beneath the platens. The 1-by-1-by-¼-inch angle iron goes to each side and the 1.75-by-1.75-by-1/8 inch angle iron will only be underneath the platen. Use enough clamps to keep the sections lined up and immobile while welding these into place.
- 7
  Weld one ¾-inch nut to the end of each 16-gauge tubing and fit the rubber handler over the opposite end of the tubing. Screw the handles onto the bolt that was welded onto each hinge.

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