Made trim tab 6T6-1 using dimensions trialed yesterday: Started wth top, inside flange. The final bend angle was formed by tapping flange around top plate with rubber mallet. Second bend formed to 117 degrees using just the brake, no secondary operations necessary. Trailing edge was bent as far as possible on brake then removed and bend further using clamping set-up on work bench. Dimensionally this came out great but the top skin had a crease caused by the sharp edge on the piece of wood used for clamping.
Had an extra blank so I quickly marked out a new tab and bent in the same sequence only this time used a piece of 1-1/4" steel bar stock (extra material from bending brake handle) to clamp down the trailing edge hoping that the narrower, radiused bar would create the bend needed without creating a crease. Alas, same results as first attempt only the crease was further back on the skin. So, after sleeping on this I'll decide whether to make a 3rd or live with another slight aesthetic defect.
