Bending the Long Guards

Since my toy brake only bends pieces up to 18″ wide, I had to find another way to bend the longer rudder cable guards. They are 25″ and 29″. Brad was nice enough to let me use the brake at his shop. It was a combination roll/shear/brake from Northern tool, and the dies were really sharp. I used Bob’s tip from the ancient Beartracks to make a protective shoe. I ran over to lowes and picked up a roll of flashing, then used the shear to cut strips that were wider than 30″ and about 3″ across. I bent those in the brake, then sandwiched the good aluminum parts between. The flashing was thin, so I ended up using about 6 pieces above and 2 below in order to get a radius that was acceptable for the 2024T3 guards.