Flat bar can be rolled the hard way from any width and thickness. For example 2" x 1/2" aluminum flat bar. The hard way refers to rolling the flat bar along the 2" width.

LIGHT DUTY ROLLING FIXTURE

A light duty rolling fixture used to roll the longitudinals for the Bezier 12.5 is shown below, with a longitudinal in the process of being rolled.

To roll, insert the flat bar between the pins of the fixture. When hand pressure is applied to the flat bar it will kink at the pins. Continued hand pressure will increase the angle of the kink. When an suitable kink is achieved release the pressure from the flat bar frame. Repeat the process again and again. This will in effect roll the flat bar. Smooth curves are achieved by small kinks placed close together.

After doing a number of processes, remove the piece and lay it on the supplied template to match the curve. If the curve looks good continue on. If you need more curve place the flat bar back in the rolling fixture and repeat the process. If you have over rolled the deck beam, just turn the beam in the other direction to remove some of the curve.

Remove and check the longitudinal on the full size patterns as shown below. Roll and check the longitudinal as many times as required to obtain the correct curve. Time spent here will be well spent.

Remember that this type of rolled part will need to be cut longer than the finish size, because of the distance between the hydraulic jack and the pins of the rolling fixture.

HEAVY DUTY ROLLING FIXTURE

The rolling jig below can be use to roll flat bar to any radius or free curve. It is used to roll deck beams, cabin roof beams, center vertical keel, and longintudinal frames. The below fixture fabricated from steel would easily roll 1/2" x 4" flat bar.

To roll, insert the flat bar between the 1" diameter pins of the fixture and a hydraulic jack. When pressure is applied to the flat bar it will kink at the jacks location. Continued pressure from the jack will increase the angle of the kink. When the chosen degree is achieved release the pressure from the jack and move the flat bar frame slightly and repeat the process again and again. This will in effect roll the flat bar. Smooth curves are achieved by small kinks placed close together.

After doing a number of processes, remove the piece and lay it on the supplied template to match the curve. If the curve looks good continue on. If you need more curve place the flat bar back in the rolling fixture and repeat the process. If you have over rolled the deck beam, just turn the beam in the other direction to remove some of the curve.

Remove and check the curve on the full size pattern as many times as it takes to get the curve correct. Time spent here will be well spent.

Remember that this type of rolled part will need to be cut longer than the finish size, because of the distance between the hydraulic jack and the pins of the rolling fixture.

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