Recently, I needed 90 degree bends in aluminum stock to create brackets for a project I have going. I grabbed $25, ran to Home Depot and after a few hours created my own metal bending tool. Quick, dirty, simple and cheap.
A Few Quick Notes:
The symbol " denotes inches.
Quantities come before descriptions of materials and are followed by an "x".
Images will be referred to in steps based on the numerical order they are placed within that step.
I used button head machine screws but in retrospect, it would be better to use flat head screws and countersink them.
Everything you need can easily be purchased at Home Depot or similar.
1) 1x 2" width by 1/8" thick flat steel stock
(I bought 36" of this for $6.97)
2) 1x 6" lengths of 1" Steel L bracket
(I bought 36" of this for $6.47)
3) 9x #8-32 x 3/8" machine screws (preferably flat head)
(I bought a box of 100 button heads for $5.80)
4) 2x #8-32 x 1" machine screws
(I bought a 4 pack for $1.18)
5) 2x #8-32 wing-nuts
(I bought a 6 pack for $1.18)
6) 9x #8 Lock washers
(I bought a 30 pack for $1.18)
7) 10x #8-32 hex nuts
(I bought a 100 pack for $3.92)
8) 2x 1/2" hinges
(I bought a 2 pack of 1.5" loose pin zinc hinges for $2.27)
This all adds up to just under $29 but if you skip the 100 and 30 packs of screws and washers and just get what you need, you should be able to get it down to $25.
1) Metal saw
(I got by with a hacksaw with a metal cutting blade)
2) Power Drill
3) 5/32" drill bit for metal
(just big enough diameter to get a #8 screw through with a little coaxing from a screwdriver)
4) 5/16" drill bit for metal
(not a must have but useful for cleaning up the edges on the smaller holes you drill)
(whichever type that corresponds to the machine screws you buy)
(For holding nuts while you tighten machine screws)
Cost: < $25 (not including tools)
Time: ~2 hours
Follow the Making...
Step 1: Cut Metal to Length
1) 4x 6" lengths of steel L bracket (see image 1).
2) 1x 6" length of steel flat stock (see image 2).
I cut these lengths the hard way using my hacksaw with a metal cutting blade attached. If you do not have any way of cutting metal you can pick up a hacksaw for cheap and get by. If you have a chop saw or band saw you can get through this stuff with, even better.
Note: Disregard the holes in the metal on the images on this step. We will take care of those in the next step.