I don’t have any sort of break or roll dies to form bends or roll edges on in the sheet metal. It is not a process that needs to be accomplished often, but on an occasional basis. In light of that I went to Lowes Home Improvement and Aircraft Manufacturing Materials and bought a couple pieces of oak to make a temporary edge rolling fixture.
I took my router and using a bit with a ¼ radius, I ran the bit down the edge of one of the boards. The other board I cut a bevel along one edge to give me more clearance to access the sheet metal edge when forming the bead on the edge. (See photo 1) I will use this fixture after getting the side panel cut and fit to the proper profile. It’s the poor man’s solution.
Next I went on to begin the process of making cuts, sanding, filing and finishing the profile for fitting to the angle and the canted forward panel. The panel is pretty close and I will do some final touches after making other pieces for the console for the final fitting process.
I finished the work session by drilling the two upper cleco holes in the main attachment angle.
