I needed to make clean straight bends in strips of aluminum for my Hidden Bookshelf Light Switch.
I had pretty good luck bending the aluminum in my bench vise, but it was hard to keep the bends square and even.
So, this is what I came up with.
Step 1: Gather the Parts
20" of 1" angle iron
10" of 5/16" steel rod
2 - 2.5" narrow hinges
2 - 1/4"x2" bolts w/ nuts
4 - screws
1 - chunk of 2x4
drill bits 1/4" and 3/16"
something to cut the angle iron (band saw, hacksaw, cut off blade, cold saw)
a small square
a vise of some type (drinking and smoking won't work here)
2 vise grips or clamps
Step 2: Cutting
Cut 3 - 5" pieces and 2 - 2.5" pieces of angle iron.
Cut 10" of the 5/16" rod for the handle.
Step 3: Setup
It is very important they are aligned perfectly.
Next, take the last 5" piece and clamp it with vise grips as shown in the second picture.
Again, make sure this lines up perfectly with the first two pieces.
Then, get your hinges and set them on the angle iron as shown in the third picture.
The hinges should sit tightly in the corner formed by the three pieces of angle iron.