I am trying to build an aluminum frame for my robot but I am having trouble finding good techniques to cut and bend it. Anyone know a good way to cut and bend aluminum for a frame? I have basic tools, but not anything fancy. The frame needs to be about 7.5 inches and relatively sturdy.
Cutting with a dremel,
Cutting with a dremel, handsaw or bandsaw. For bending a vise would be good, use two wooden bars to cover the vise and then bend the Aluminium sheet with antother piece of wood.
A bit work before bending to build this: http://www.instructables.com/id/Homemade-Mini-Press-Brake/
or simple here: http://runawaybrainz.blogspot.com/2011/11/diy-how-to-bend-aluminium-easy-way-with.html
Any sharp woodworking tools
Any sharp woodworking tools will do. Carbide is the best. I have used a circular saw and a jigsaw successfully, just remember to deburr after- you wouldn’t want any sharp edges.
Metal working
You need to check out your local Harbor Freight, (www.harborfreight.com), They have all kinds of inexpensive metal working tools & accessories including shears & breaks. These things are on sale most of the time and there is always a 20% off coupon which makes them even cheaper.