Custom corrugated sheet steel panels for home DIY project. Brake job anyone?

[m_c]

Robin, the bends are 2m long...


Just thinking, but is there any structural reason why the panels have to be done from 1mm thick sheet?
Could you get away with thinner sheet?

As for dies, given the number of parts you want to make, you could probably get away with dies made from untreated steel, and polished up. I've seen a good few homemade dies used, and they're good for short runs where the durability of commercial dies isn't needed. Still need to find somebody with a big enough press though!

[Robin Hewitt]

Robin, the bends are 2m long...

Blimey, I missed that

Fading eyesight, large screen, small text, mutter, blah...

The problems suddenly become clear.

The job is seemingly easy but labour intensive, especially if he's winding the backstop by tape measure. There is too much potential to go wrong and have everything end in acrimony.

It is very hard to convince a workshop to take on a tricky job and give it their best shot. They have past experience and simply won't believe you. It is not fun going back to the machine to try again after wasting half an hour placating someone with unreal expectations waving digital calipers in your face.