"Bruce Simpson" wrote in message
...
On Fri, 08 Aug 2003 17:54:45 GMT, "Ed Huntress"
wrote:

It's done with a slip roll (roll former). I haven't done this since high
school shop, so you may want to get some advice that's more up-to-date.
g

There are two ways to do it. You can set the back roll at an angle, if
your
slip roller is made for it; or you can "drag" one end of the work through
the rollers, so that the wide end is moving faster through the rolls.

In my high school shop class we had to do it both ways. I never really
got
the hang of dragging the work, but I think it's a matter of practice.

Any good HVAC or sheet-metal shop should be able to do it for you, pretty
cheaply.

The problem is going to be the 1 inch end -- the smallest regular slip
rolls I've seen have rollers about 2" in diameter.

If the rollers are too thin then they bend in the middle and
everything you roll ends up having a tighter radius at the ends than
it does in the middle.

This job might require some judicious use of hand forming to get the
small end formed. You'd be surprised what can be done with a steel
dolly (a piece of 1" diameter steel rod in this case) and a well swung
hammer :-)

--
you can contact me via http://aardvark.co.nz/contact/

Oh, yeah, that's pretty small. I've seen small slip rolls, but I don't know
if they would handle 1 inch directly.

If you can get close, you usually can pull the form around to the final
shape. 22 gage is quite thin.

Ed Huntress