I don't own a bandsaw or any decent metalworking tools for that matter. When I need to make a bracket or an adapter plate or whatever, I draw it up in CAD and email the dxf to a local laser cutting shop. They turn orders around pretty quick, and a part like this will cost $30-$40 - can't go wrong.

I thought I'd share this one with you fab gurus, because I'm looking for some input. Imagine that I'm going to fold the left side up toward the viewer at 90*, and then fold in the triangle pieces so that their free edges lay flat along the larger part of the bracket (pointing to the right). I'll then weld those seams to complete the part.

My question is, if I'm using 1/8" material, should I use a 1/8" gap (as shown in my drawing) where this bend will take place? Is there some sort of sheetmetal math that will tell you what the ideal gap would be? I'm sure I can make it work as shown but I figured I'd see if you guys could point me in the right direction. Any feedback is appreciated.

Pic:

 

Looks good. I wouldn't leave any gap there.

 

the gap would depend on the radius of the bend

 

Whats the minimum cut diameter of the laser (how much material does a single pass remove)?

 

if he is going to use a bench-top brake its best to leave the 1/8" gap to make it easier to bend.

 

Jeez Matt just when i thought i was over-engineering parts for my car you have to go and show me up. lol looks good man.

I assume you are planing on running a couple beads on the tabs after you bend the, if so then i think the 1/8in gap will be fine considering the bend radius and the remainder will allow for a good weld.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by jj07 &raquo;</TD></TR><TR><TD CLASS="quote">Jeez Matt just when i thought i was over-engineering parts for my car you have to go and show me up. lol looks good man.

I assume you are planing on running a couple beads on the tabs after you bend the, if so then i think the 1/8in gap will be fine considering the bend radius and the remainder will allow for a good weld.</TD></TR></TABLE>



Yeah, I figured I could fill whatever small gap existed during the welding process.

Wait 'till you see where this is going to fit. I mocked everything up last night and am pretty excited how it will all go together in the space between the tank and the rear crossmember.

 

I can post up some pics of the way I did mine but it will not be for a week or so since I am out of town.

 

usually it makes it easier for them if you draw it up in its folded state. flat patterns like what you have can be tricky unless you know how to calculate bend allowances. instead of putting the 1/8" dimension for the bend relief just put "min bend relief" and they'll know what to do with it.

also when you dimension to features try to do it from the edge of the part. for example the way you have your 5.000 stacked with the .125 and the 3.000. instead of that, put an overall dimension of 8.125.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by T4 Neon &raquo;</TD></TR><TR><TD CLASS="quote">



Yeah, I figured I could fill whatever small gap existed during the welding process.

Wait 'till you see where this is going to fit. I mocked everything up last night and am pretty excited how it will all go together in the space between the tank and the rear crossmember.</TD></TR></TABLE>

Hahaha same place my pump and filters are.... lol

 

bah...remove the recess and just bend it. If you weld on it...it makes it look as if you messed up designing the bracket and had to have it fixed. im with tony on this one.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by .RTErnie &raquo;</TD></TR><TR><TD CLASS="quote">bah...remove the recess and just bend it. If you weld on it...it makes it look as if you messed up designing the bracket and had to have it fixed. im with tony on this one.</TD></TR></TABLE>

I think you missed the part where the triangle "wings" get folded in at the end, to become gussets. There will be welding involved anyway.

So I've heard, leave it 1/8, so it bends easier. And I've heard, leave the gap as small as possible. I guess I'll try it as-is and post the results in a couple days.

 

Do you have access to solidworks? It has excellent sheet metal tools.

 

You may want to make the flanges on the sides of the vertical bracket extend the entire length of it, like this:



to give it a little more strength.

According to solidworks, if you make it out of 6061 aluminum, it will weigh .53lb, out of steel it will weigh 1.52lb.

 

cool program.... how much does a non student version cost?

 

like 5g's

 

thats nice setup. a bench vise and 3/4 strap aluminum is how i did mine. the bench vise brake is my friend.

for the hell of it, i could have used a bracket like that:

 

Wow, thanks for the model! The little extra notches you added should help make the bend easier - I'll try to incorporate those.

I wanted to keep the gussets smaller, so that they didn't interfere with the cylindrical body of the pump, or the inlet / outlet fittings. It should be plenty strong as-is.

 

got a pic of the pump?

 

I dont think you even need to consider the gap, the actual bend "line" will determine if the gussets lay flat or not, it is going to be all relavent to getting the bend exactly right.

If i were to fab this myself i would cut all pieces and tack them together, because I do not have the proper tools to make it perfect the first time.


I think the gap in the picture is only there indicating slotting it to allow bending.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by k24em2 &raquo;</TD></TR><TR><TD CLASS="quote">got a pic of the pump?</TD></TR></TABLE>

little large, cant resize at work but here is a 2015a basic size up til the really high hp pumps:

 

[QUOTE=boostedcivicsir]

Nice sig , sounds familiar

 

So is the pump mounted over the 5x5 part of the bracket?

 

the bottom of the pump attaches to the smaller tab

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by agrn93ls &raquo;</TD></TR><TR><TD CLASS="quote">the bottom of the pump attaches to the smaller tab</TD></TR></TABLE>

duh , i am assuming he wants the pump to be over the larger part.