- 1). Cut the sheet metal to size using a bench shear, band saw or jewelry saw.
- 2). Use a scribe and a ruler to mark a line where you want to bend the sheet metal. Be sure the line is straight.
- 3). Place the sheet metal in a vise, box and pan break, bending break or press break and clamp it so it will not move. Line up the scribed line to the point in the break or press where you will make the bend. The vise is the low-tech option for those with no access to a break.
- 4). Lower the boom on the break until the sheet metal is bent to the angle you need. Measure the angle and adjust the bend, if needed. If using a vise, bend the metal over the vise with your hands until the sheet metal will bend no more. Continue bending by hitting the sheet metal with a weighted rawhide or plastic mallet.
- 5). Check the crease of the bend to be sure it is even. Finish with a weighted rawhide or plastic mallet, if needed.
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