40" - 3 in 1 -Brake,Shear,Roller - Modified

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planecrazzzy
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40" - 3 in 1 -Brake,Shear,Roller - Modified

Post by planecrazzzy »

OK... This is a COOL TOOL !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

I would NOT get anything smaller than 40 inch...

First thing I needed to do... was get this 600lbs of tool on wheels...

I used shopping cart wheels...swivels ...plenty strong , I've used them on other HEAVY things.

The Tube for the stand is 1/16" wall - 1" X 1" tube , Mild Steel...
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Gotta Fly...
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planecrazzzy
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Re: 40" - 3 in 1 -Brake,Shear,Roller - Modified

Post by planecrazzzy »

Here's something I thought might come in handy...

Since I have swivel wheels... Sometimes I want the tool stationary / SOLID...

I made two of these stabilizers... they will fit on any corner...

I can put both in front , I usually put them on the end I'm cranking on...

The picture doesn't show the plywood I put on the lower tubes for a shelf...

It is "Notched" for these stabilizers to fit... Turning these BY HAND , they will LIFT the tool.
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Gotta Fly...
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and build your wings on the way down...
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planecrazzzy
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Re: 40" - 3 in 1 -Brake,Shear,Roller - Modified

Post by planecrazzzy »

In these pictures I have three Mods...

One.. I added a "Drop Pan".... handy for catching pieces cut off by the Shear...

Two... I made spacers to keep the handles from hitting the side of the tool during Rolling

where the handle needs to go round and round... another "Tip" during THIS operation...

I disconnect the Brake/Shear.... No sense in cycling it... it's more DRAG...
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Three... I changed the "Hold Down" Spring to a heavier one.... Another tip... If you REALLY

need a close tolerance shear cut.... Clamp the piece in place ...
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Gotta Fly...
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and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Re: 40" - 3 in 1 -Brake,Shear,Roller - Modified

Post by planecrazzzy »

More Mods...

OK... The Backstop that came with it was CRAP !!!!!!!!!!!!!!!!!!!!!

The only part I used was the Clamp/Blocks that hold it in place...

I put a regular angle on it.... But found I need the stop to get CLOSER to the Brake Die...

I put a STOUT piece of Cold Roll Steel on it... It butts right up to the die if needed...

Since it was pretty stout... it stayed straight during "LIGHT" welding...
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Another improvement was a "One Piece" upper die... The Pan die's work great...

But there "are" slight dimples when your making long bends... Hardly noticeable...

But I just Happen to come across a piece of Chromoly 7ga flat plate...Perfect !!!

I did have to tack slight shims at the top , in order to get it centered...

I have it the SAME size as the Pan Fingers... So switching them is SIMPLE !!!!
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Gotta Fly...
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planecrazzzy
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Re: 40" - 3 in 1 -Brake,Shear,Roller - Modified

Post by planecrazzzy »

This is a cool "mod"... Not really a mod... just a "Trick"...

I've found that sometimes I needed "Tiny Bends".... I had to bend it , then shear off the extra...

I experimented with Key Stock one day... 1/4" X 1/4".... three pieces...

Wow... it works PERFECT... They stay in place... and make VERY small bends !!!!!

So I got three 40" pieces I keep on the back of the tool , ready if I need them.
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In the sample Bends... You can see a "Stock" Die , it's smallest bend...

Compared to the Bend I make using Key Stock in the lower die...
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Gotta Fly...
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Sometimes you just have to take the leap
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planecrazzzy
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Re: 40" - 3 in 1 -Brake,Shear,Roller - Modified

Post by planecrazzzy »

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Another Mod I needed was to make the roller slots bigger...

I was only trying to roll 3/8" tube...

But I think the size they had was Metric ... All I know it was too small...

I rotated the roller(s) while holding a small grinder...(one roller at a time)

I had the grinding wheel cocked... it would touch both sides...

Better be skilled if your gonna try this "Free Hand"...

Remember... Success - It comes in CANS !!!!!
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In this picture, Note the Shear/Brake is disconnected during "Rolling"... Much easier.
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Gotta Fly...
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Sometimes you just have to take the leap
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planecrazzzy
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Re: 40" - 3 in 1 -Brake,Shear,Roller - Modified

Post by planecrazzzy »

Wrapping up the Mods on my 3 in 1 tool...

I needed to take "off" my shear blade... and with boards and SLEDGE hammer...

Getting the thing straight... There is an ADJUSTING bolt on the back side of the blade...

It will let you "Tweak" the blade straight by tightening it...

Well... The Factory workers have had a HABIT of Tightening these damn bolts so much,

that it pulls the blade out of whack... even when the bolt is backed off...

I went to a friend's house and helped him get his shear blade straight also...

Tip... While your POUNDING it back straight... ( Using BOARDS on it to protect the surface )

You "CAN" pound it a pinch extra... This lets you actually use the adjusting bolt !!!!
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I hope these Mods help you...

This is a Cool Tool... Even BETTER with some of these Mods...
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Gotta Fly...
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Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Re: 40" - 3 in 1 -Brake,Shear,Roller - Modified

Post by planecrazzzy »

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Tool in action...

Making my Fuel Tank... All three sections were used , Shear , Brake and Rollers, Full Width.

Just having a Tank made is close to $500 bucks... This tool PAYS for it's self , over and over.
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In a couple of these pictures , you can see why nothing less than the 40" version will work...

Even if the pieces isn't 40" wide.... if it's on an angle like these door skins...

It'll take up the full blade in a hurry...

Notice the upper cover is moved "back" , out of the way...

This lets you "LOOK" , straight down the "Shear Line" , for exact cuts !
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Gotta Fly...
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PS If I wanted to... I could sell this Tool for what it cost me , and the rise in new prices...
especially since the kinks have been worked out, and improvements have been made.
Sorry... I ain't a gonna sell it ! Git yer own...
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Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
wdyasq
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Re: 40" - 3 in 1 -Brake,Shear,Roller - Modified

Post by wdyasq »

Interesting use of the keystock for 'shrinking' the die.

Thanks,

Ron
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planecrazzzy
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Re: 40" - 3 in 1 -Brake,Shear,Roller - Modified

Post by planecrazzzy »

Back to the Subject of Shrinking the Die...
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Using it for my last project... Bending .032 6061 Aluminum , 33.5 inches long...
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I was under-powered... Hanging on the Handle like a Monkey...Going from Side to side... No Joy...
I got someone to pull a handle... and we Rocked away another Bend... Hmmm...
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I figured I needed to make something to pull both sides down together...
First I thought of a Board across the handles... Then the Rope... Ahhh
The leverage I get from STEPPING on a rope is power to spare.
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Now I have the rope at the length I need, at the tool... Also to REMIND me.
You can see it's just a skinny rope... But more than strong enough.
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Gotta Fly...
You do not have the required permissions to view the files attached to this post.
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Re: 40" - 3 in 1 -Brake,Shear,Roller - Modified

Post by planecrazzzy »

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Cool Cut... I saw this from the monthly EAA email...

Builders tips...

They put a cut at each side of the sheet, placed it into the shear and pulled back until they felt the cut "catch" the shear edge...

Then cut.

I tried it....not quite as clean...one cut made the piece go up...the other went down...
pliers to get it right... and it was scared up.

next one I thought I'll turn the tool over to solve this.... Hmmm, nope

So What I have that works is Left hand and Right hand snips.

This puts a tiny "Stop" on each side , in the correct orientation without messing with it.

The mark becomes part of the cut...

If I really need a clean cut , I'll do it the old fashion way...

But this is handy for quick accuracy.

Gotta Fly...
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This has been very handy ,I use it a lot
You do not have the required permissions to view the files attached to this post.
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Posts: 1154
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Re: 40" - 3 in 1 -Brake,Shear,Roller - Modified

Post by planecrazzzy »

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Something that I have fought with for years was the Shear blade adjustment.
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One side Stayed in place , the other side would loosen after a few revolutions.

That was MY fault ...
When I was going to add a set screw , I found out that there WAS ONE ...
It just needed to be screwed in a little more .
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So, on with the Mod...
First picture ... Those little washers were the guides .

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I stacked two washers , a regular washer and a bigger Fender washer ...Ooooops
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One side had clearance , the other side didn't .
Afterwards I removed one washer and straightened the bolt ...
The SET SCREWS in the back helped to get a solid base for the guides .
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I think it's going to wear better than with those little washers .
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Gotta Fly...
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You do not have the required permissions to view the files attached to this post.
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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