4 hours - make a brake out of wood. This used (pretty expensive) oak and birch at 4-foot lengths. Subtracting a 4" door hinge from each end leaves a theoretical 40" capacity. This turned out to be pretty precisely made - I countersunk the hinges to get the hinge axis tight to the edges of the wood, so when the hinge is rotated, the wood only separates about 1/16". This did not work well for the 1/2" wide flange - not enough material pressing on the bending boards. The part slid back under the clamping board, so I secured it with screws through the tooling bolt holes (I had only drilled the holes to 1/8" dia, not the final 1/4" dia). The clamping board slid back, so I secured it to the base board with screws. Then the bending board bent (and I made it into an angle with a second piece of wood, so I can't bend it by leaning on it, but the force of metal will bend it). So I just hammered the 1/2" wide flange. Then the 1 1/2" wide flange bent ok - not quite to 90 degrees, but at least there are no hammer marks. Looks almost like a kit-built part. My fluting efforts on the curved flange show through to the large flat face a little, though. 1 hour - finish hammer forming the two formers after bending the 1/2" and 1 1/2" wide flanges on the brake.
