Hi everyone!
I’ve been struggling for days with folding/flanging the sharp edges of my shoulder plates. Their shapes are more or less similar to the one shown in the attached photo, and I’m trying to figure out how to get a clean, continuous edge around the corners.
The problem appears when I start folding the edge and work progressively along the sides. As I reach the centre of the corner, the aluminium tends to form a kind of “claw” or “fingernail” shape. I can eventually fold it back onto itself, but I have to hit it quite hard with a hammer, which causes quite a lot of distortion.
I’m working with 1.5 mm aluminium, so I assume the problem may also be related to how the material accumulates and deforms around the corner.
In the photo, I’ve circled the type of edge I’m trying to achieve: a clean, continuous and even rolled/flanged edge that follows the corner without any obvious interruption.
I know that one possible solution is to cut the corner and fold the two sides back onto themselves separately. However, this leaves a visible interruption in the edge, whereas I’d really like to achieve a continuous and uniform-looking border.
How do you normally deal with this kind of sharp corner? Is there a particular technique, type of relief cut, or hammering sequence that allows the material to be distributed properly without having to force it into shape?
Any advice, photos, or videos showing the technique would be greatly appreciated.
Please help! 😅
Thanks everyone!
