1000mm diy brake press, now committed money!

[Bristolbulldog]

I need to learn to tig, and I want to Re-skin the tailgate on my classic range rover and turf it into a locker.

So, I'm going to measure the width of the tailgate tomorrow, and that's how wide my brake press is going to be. I'm rarely going to be bedding heavy stuff as I'm more likely to cut and weld it.

I've just ordered up a rusty old rsj 4.5 meters long, 10." high, and 5.5" wide. I have no idea how thick the steel is, but I'm guessing 6mm+

I was going to go for the usual H press, use the rsj for the top and bottom of the actual press area (possibly put in some webs, or angle to limit bending) and then 6mm angle doubled up in some way to make the uprights.

I've got plenty of 6mm offcut plate to use on this if required as well.

I'm looking at putting in 6mm shelves, probably wedge re-enforced to lower the bottom of the press on, as opposed to the cut holes and bar, as I think with the little plasma I have on order, i won't be accurate enough with it. Whereas I can tack these tabs perfectly in place and get it spot on.

I'm a good mig welder, but terrible tig welder, and this to me seems like a good project to learn on.

I've got an r-tech 200A dc digital tig, with far too many settings on it, and it confuses the hell out of me even after reading the confusing manual. I can seem to set the amps, pre and post flow etc. I'm inclined to leave pulse alone, as that's confusing. I understand the principals, but they use slightly different terminology to guides on how to use pulse, so I can't figure exactly what's god settings,

 

[zardoz]

I get the re skinning the tailgate part. But "turf it into a locker" ? Is that some sort of weird Bristol parlance ?

Here are some home made press brakes in case you havent decided on a plan yet.

 

[Robotstar5]

I get the re skinning the tailgate part. But "turf it into a locker" ? Is that some sort of weird Bristol parlance ?

Turn it into a locker?

 

[Angusdog]

I'm rarely going to be bedding heavy stuff

I didn't come here just to take the mickey but I couldn't let this one past...

Incidentally the forces on a 1000mm bender will be considerable to I'm keen to see how this goes.

And speaking of typos, this is the label on my (chinese) brake:

 

[Bristolbulldog]

Ah, my typing is terrible on an ipad. I seem to think I can type fast and it's easy to undertsand it!

I won't be bedding the brake press, or turfing it in any manner .

I've some bad news. The tailgate skin is 1400mm wide. Will a 20t press bend 1400mm stainless steel at 1.5mm

I've looked at a few charts and they aren't incredibly clear ;(

Rsj turns up Saturday, so I'll know the thickness then.

From looking at 75t presses on ebay. And google images it seems 6mm angle on each vertical "post" of the H press (so 4 lengths) seems to be enough. It's just the bar at the top and the bottom.

I have no idea of the forces of 20t over 1400mm but I imagine it's pretty huge. As these are rare jobs, if I cannot get the strength I could fab a few verticals that I fix in place more toward the center to lessen the overall span?

I wanted to go for an air bottle jack, so 20t is the only reasonably priced one I can get. But I have a feeling I'm going to need to go for a 30t manual?

Help appreciated. I'm sure this will be rather interesting once I start building it probably this weekend.

 

[Bristolbulldog]

Turn it into a locker?

Yes, that's the plan. The tailgate is about 4" deep, no idea why Landrover designed it in such a way.

I have a spare wheel holder off the back, with a 35" tyre on it, so it needs a solid anchor, so I can re-enforce the outer skin, and also put a locker for tools, recovery stuff or whatever in the actual tailgate.

The fuel tank it currently in the boot as it's bobtailed, but that another project a wide press will help with massively! New fuel tank!

 

[KemppiFrog]

Ben8vtept this up on a another thread

http://www.mig-welding.co.uk/forum/attachment.php?attachmentid=37671&stc=1&d=1376681706

Hope it helps
KF

 

[Bristolbulldog]

Made a start

It's now 1500mm wide as the tailgate is 1400 and then I need to add some vertical guides I've seen on others designs.

 

[octo0072000]

you would be better with two jacks over that width

 

[Lawnmowerboy]

make up some sort of tandem handle in the middle

 

[Bristolbulldog]

I was thinking of two jacks, as bending the planned 1400 mm 1.5mm stainless apparently needs 22 tonnes ish, and I want to use those air jacks (20 tonnes each), on a foot pedal. Will they lift identical though?

What's a tandem handle?

Totally open to any suggestions on this as it's my first bit of non vehicle fabrication work.

I've heard rsj's can twist. It's made from roughly 8mm steel top and bottom, and 5>6 mm in the middle. It's ridiculously heavy, but will it need bracing?

I was thinking if it did to use 6mm angle iron end to end in each part of the I beam corners, making it 4 lengths, but I've seen another thread where they just put some vertical pieces in.

Unsure if I will need it or not?

 

[Lawnmowerboy]

I meant if you were to use 2 hydraulic bottle jacks you could make a handle up to operate the 2 jacks simultaneously. Though air jacks would be good.

 

[Bristolbulldog]

Long day! Should of got that!

 

[Bristolbulldog]

Ok, I've updated my basic idea to two air jacks (20t each).

I'm currently on the lookout for someone who could make me a 1400mm wide press blade / edge. I do t want to use a piece of angle or square if I can help it.

I'm more than happy to join it, and refinish, but I have no means of making that long blade finish of less than 90 degrees. I've also seen the ridiculous retail prices...