Bench Folder

These are available very cheaply every where but Australia but this builder decided based on previous experience that one was required - I gritted the teeth and paid the bill.  

A modification that must be undertaken is to modify one of the the sharp folding edge's to a radius. The aluminium used in construction of aircraft will NOT fold through a sharp edge to 90 degrees without cracking. The radius is easily created using files, begin by filing a 45 degree chamfer 2 mm wide across the full length, then chamfer the sharp edges and finally blend into a radius using a rolling action and draw filing. Finish with 240 grit emery strip by lapping across the full length blending all the edges together.This radius will be good to about 0.6 mm [0.025''].

This tool can also act as a poor mans gillo when combined with a Ofla Knife. With the un-radiused edge of the clamping bar placed along the cutting line and clamped to the frame it frees the operator to use two hand to cut thicker sheet up to 1 mm [0.040'']

Clamping bar acting as cutting guide

After cutting through about 50% fold and break free

Cutting smaller opening - be carefully to stay withing cutting area as the Ofla knife
scribes quite deeply with each cut

These tools have proved invaluable in fabrication of side panels and brackets to mount hardware.