1 This is what I have come up with, thanks and a hat tip to my younger brother in Kentycky, Chris, who has a new-to-him CNC machine. I sent the diagram and some aluminum rod and he returned some really nice flanging dies that work like chanpions! thanks much , little bor!
I use silicone spray as a lubricant. Hole size is inportant, so way beck ago I did some tests and set the old fly cutter to just under 3 and 4 inches so as to make a tight fit on the flanger. doong that made the actual flange the same 'thickness' circumfrencially, as well as centered where I needed it.
2 action is had by getting the large wrench out and twisting the nut until you cant tighten it any more. Doing the really snug opeation ensures that the non flanged area of the metal near the hole is nice and flat, while the actual flange conforms to the angle of the flanger...so to speak! It works great, and the afforementioned chapter visit could not understand how I got them so nice. I demonstrated to them. I guess they were pleased. I dont really know!
3 This shows how tight the fit onto the flanger the hole needs to be.