Sun Aug 09 2020

Roll forming LED joggle strip

Instead of spacer strips, I decided to switch back to joggling a thin strip of aluminum. I think the best way to do this is to roll form the joggle. So, I need to build a basic roll former. I went to Home Depot and picked up a strip of 3/16" thick x 1 1/2 wide steel and marked out some cut lines and hole centers.

After cutting a portion of the strip off, I drilled some starter holes...

...then drilled them up to .500".

I used a cutting disc in the angle grinder to cut off the individual pieces.

Also nipped off the corners with the angle grinder.

Clamped all these pieces up on a bolt and chucked them in the lathe.

Gave the little lathe a workout turning these down.

Here are the little rollers. Tomorrow, I'll radius the edges so that they form a nice .093 radius for the bends of the joggles.