How to Create smooth waves in sheet metal

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DesertFabworks
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How to Create smooth waves in sheet metal

Post by DesertFabworks »

I'm sure people have seen some of the Wavy flags done by a few of the plasma cutting companies out there. I would like to know if anyone knows what process they are using to make these nice smooth and equal waves across their sheet metal flags. I have a slip roller but I do not think you could make repeatable consistent waves again and again. Maybe they are using a custom press? Not sure but I would like ideas on doing it.

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Re: How to Create smooth waves in sheet metal

Post by DesertFabworks »

This is what I'm talking about. I used my slip roll to do this but it was a long painful process. I'm looking for an easier way. This is 14g cold roll steel in the picture.

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Re: How to Create smooth waves in sheet metal

Post by acourtjester »

A simple process would take a few lengths of 2" tube with some way to hold them in position. like 4 tubes below the metal and 3 above placed between the 4. And a length of 2X4 across the top that you use a press to push down to form the waves you want.
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Re: How to Create smooth waves in sheet metal

Post by little blue choo »

Like acourtjester said if I was going to make these I would take 2' pipe, 4 along the bottom, weld them together along both ends with some 2x2x1/4 angle, then build a top the same way with 3 pieces of pipe. I would them hinge them on one end and attach a handle on the other end so I could pull down on it and form the metal. If you wanted to you could also make it to be used in your press but would probably be quicker to just use the pull down handle. Remember the longer the handle the less you strain! I think I will build this. I love fabing! I will enclose pictures when finished.
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Re: How to Create smooth waves in sheet metal

Post by tnbndr »

I use my roller but don't worry about making them all even and the same. I don't like that look so I don't try to repeat it.
Ever seen a flag blow in the wind with even furls??? IMHO
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Re: How to Create smooth waves in sheet metal

Post by DesertFabworks »

Granted my roller is not powered and is not that big but it took me about 20 min to make the short little piece in the picture and a lot of cranking. I could not sleep last night so I fabricated this little guy. I was able to make the long 5+ foot wave piece in under 3 min with the push of a button instead of bunch of cranking. Its nice because I can make perfectly uniform waves or I and make them all different by changing the depth of each press. I can also make them at an angle or straight on. I think it will work for what I need. Its most likely overbuilt I think I can put 10 gauge through it without a problem cant say that for most rollers.

I went with 3" tubes for wider smoother look to the waves.

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Re: How to Create smooth waves in sheet metal

Post by acourtjester »

Now that is what I'm talking about complete with spring ejectors :) :lol:
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Re: How to Create smooth waves in sheet metal

Post by little blue choo »

AWESOME!!

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Re: How to Create smooth waves in sheet metal

Post by DesertFabworks »

Here are a couple of my first projects with this new bender. I think they came out pretty nice. I still have to do the finishing on them but its a good start.

I can do up to 22 in wide with this set up.

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Re: How to Create smooth waves in sheet metal

Post by _Ogre »

nice work desertfab :D
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Re: How to Create smooth waves in sheet metal

Post by Nacs Fab »

As always Nice work!
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Re: How to Create smooth waves in sheet metal

Post by plasma_burn »

Over in the Viking or American Flag thread SckotchandIron spends about 10 minutes with the slip roll.
http://www.plasmaspider.com/viewtopic.p ... d&start=75

Maybe some kind of manual radius bender, although it may take two guys to run it.

Image

Trick tools has one with a large bend radius also.
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https://www.youtube.com/watch?v=Z50Qlk-Iko8
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Re: How to Create smooth waves in sheet metal

Post by Nacs Fab »

Thanks for the Share Plasma_burn. I think I may take a stab at fabricating one of those radius brakes. Need to start gathering materials!
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Re: How to Create smooth waves in sheet metal

Post by gamble »

looks nice! now how do you hang it ?
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Re: How to Create smooth waves in sheet metal

Post by DesertFabworks »

Lots of options on hanging. Small pin nails in the valley sections. Weld tab on back, weld tabbed wire,
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Re: How to Create smooth waves in sheet metal

Post by gamble »

Every time I weld a tab on the back you see the haz on the front the front and I can never get rid of it
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Re: How to Create smooth waves in sheet metal

Post by DesertFabworks »

Most of my signs I use 14 g steel and I watch my heat if I do get a mark on the other side I hit it with a wire wheel on a grinder first and then lightly sand to match the surrounding and you can't tell it ever happened
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Re: How to Create smooth waves in sheet metal

Post by tnbndr »

Every time I weld a tab on the back you see the haz on the front the front and I can never get rid of it
Just hit the front side with a 120 grit flap wheel until the haze and slight penetration blend back in with the flat steel. Doesn't take much, you will see it disappear.
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Re: How to Create smooth waves in sheet metal

Post by gamble »

tnbndr wrote:
Every time I weld a tab on the back you see the haz on the front the front and I can never get rid of it
Just hit the front side with a 120 grit flap wheel until the haze and slight penetration blend back in with the flat steel. Doesn't take much, you will see it disappear.
Done that but when I paint it then it shows up lol
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