Bending metal . .  . something I know about for a change. 

When you bend the angle iron, put some relief on the inside of the corner with a
grinder or a file.

If you don’t, the corner will be neigh impossible to close to a true 90. You’ll
have either a gap on the inside, or a rounded corner on the outside.

Depending on how much load it needs to take, and which way the load is going,
etc., I'd relieve as much as 50% of the material inside the bend. In fact if I
was doing it I’d probably take more and shoot a couple of spot welds into it but
if you don’t have a welder I wouldn’t take more than 50%. I know even 50 sounds
like a lot of material to take out but if you get the 90 in there as 2 even 45’s
it will close right up tight when you bend it, and like any joint it’s stronger
if nothing is moving and flexing. And in the long run it’s less material than
you’ll take off if you just bend it then have to futz around with the grinder to
get rid of the gap, or the radius on the outside.

Depending on the size of the brackets and how soon you need them, I could be
persuaded to knock them up and mail them to you. My 10 year old has been asking
for another welding project . . . I’d just need to get a decent weather day to
haul the metalworking stuff out of the back of the shop into the horse paddock.
I won’t grind steel or weld in the shop since I started working wood in there.
The grit is impossible to control, and it's murder on blades and irons. Dragging
the metal stuff out is a lot easier than moving all the planes and chisels, etc.
and having to “sanitize” all the grit off everything.

MPf

PS: amen on the blueing . . . . since we moved to humid NC all of my blued stuff
stays in the safe and I only take out the tenifer and stainless


> On Sep 4, 2015, at 1:02 AM, Bart Nadeau  wrote:
> 
> If this for exterior use, do you really think the gun blueing will hold up in
the weather?
> 
> Bart
>> On Sep 3, 2015, at 8:56 PM, Champ Herren  wrote:
>> 
>> GG,
>> I am working on a project that will necessitate me using 2+" angle iron for
>> exterior corner braces.  Here are my thoughts.  As always tell me if you
>> see something amiss or a shortcut.
>> 
>> I am going to shape the angle to a more aesthetically pleasing shape. The
>> screw holes will be counter sunk to be flush.   Then I am going go use
>> sandpaper and polish the absolute crap out of it.  Afterwards I want to use
>> gun bluing and and create a classic finish.
>> 
>> Any thoughts about this scenario? I value your advice and collective wisdom.
>> 
>> Thanks,
>> 
>> Champ
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