...............................................--- Mounting Brackets Part IV ---
One more page of brackets and these are the ones you might have to have someone else weld up.
..............
Start with some long and short pieces of aluminum and ...
..............
... mark the centers.
..............
Bend the long ones over in the vise at the center mark.
..............
Finish the bend using the vise jaws and...
..............
... insert a piece of 3/16 aluminum to create a 'u-shaped' fold.
..............
The finished first step.
..............
Since you can't get the fold perfect start with a piece a little longer than needed and then cut it back so that both legs are the same length with a hacksaw or in my case using the mill.
..............
Drill a 1/4 inch pilot hole that can be enlarged later if needed.
..............
To round the ends or corners on these pieces I just find something that has the radius I want and use it along with a magic marker and ...
..............
... then cut to the mark with the band saw or a hacksaw and finish with the grinder.
..............
The shorter pieces we started with get 4 mounting holes drilled in them. I stacked pieces, left arrow, so that I could drill a number at the same time.
..............
As before the corners were marked with something round and rounded off.
..............
I used the end mill to mill a slot down the middle, but a drill press to make end holes and a saber saw could be used to cut the slots.
..............
The long pieces that we started with are inserted into the slots and ...
..............
....welded into place on the top and the bottom side. The brackets above will hold a piece in double shear with a bolt.
..............
The same procedure was used to make some ...
..............
... single shear brackets.
..............
A close up of both. Now let's use all of the brackets for something.
