how sheet aluminium may be cut using nothing but a knife and a metal straight-edge.
Step 1: Cutting Aluminium Sheet
Sheet aluminium can be cut without the need for a guillotine or tin-snips which tend to deform the metal.
With the aid of a straight-edge and a sharp knife "score" BOTH sides of the aluminium sheet. This weakens the aluminium and creates a "fracture line".
Place the "fracture-line" over the edge of a table and bend the overhang SLIGHTLY downwards. Flip the sheet over and repeat. After a few "wiggles" the sheet will fracture along the cut-line leaving a clean break as shown in the above photos.
With care and patience full-size sheets of aluminium can be cut using this method. Create a long fracture-line then progressively bend the sheet from one end to to the other.
Step 2: Folding Aluminium
The metal-folder is made from two right-angle sections of metal. My folder is made from aluminium but "angle-iron" is okay.
The spacing between the two nuts and bolts determines the maximum width sheet that can be bent.
Prepare your work:
Mark where you want your bends.
Remove any unwanted corners.
Fold the aluminium:
Now slip the aluminium sheet between the two angle-s and roll the bender forwards while exerting downward body-weight pressure until the fold is 90 degrees.
Step 3: Corner Folds
Make a slot along one edge of your folder to accommodate the first bend.
Position the first fold such that it will enter the slot when the bend is complete.
Complete the bend.
The completed corner is shown in the last two photos.