First off, I'm a DIY kind of guy that believes in doing as much as I can myself, if I can fashion a way to get it done I will! I'm sure I'm not the first person to do it this way but I can't remember if/when I've seen it before. I'm building a winch mounting plate for The Warhorse
and I had envisioned it being bent and then welded at certain points for strength but I don't have a bender and I'm not about to pay some shop an outrageous rate to do it for me plus... where's the fun in that! Lol. I do have a 5" metal bender for my bench vise but I don't think it would've cut it even if the jaws were tall enough to give it a try so I got to thinking and I figured if I cut a relief with the angle grinder (loaded with a thin cutting disc) that could maybe work! I've never tried this before, let's see what happens!
After cutting the reliefs I chucked it in the bench vise with a heavy piece of angle iron (to span the whole bend), gave it a go and it bent nicely right up until the 45 degree mark which is when the edges of the relief touched each other...
So I grabbed the grinder and cut another relief along the bend but now that I saw the flaw in my plan I used a worn grinding disc to open up the relief cuts for the others bends.
I tossed it back in the vise and viola! 90 percent of the way there! A little persuasion with the BFH and it was now sitting at 90 degrees! (not pictured)
That's all folks, class dismissed! Get out there and bend some metal!