Chair  2                                                8-2023

 

Making A Foot Step Continued

 

I'm using the table on my milling machine to clamp the sheet metal down. I placed the metal between two pieces of wood making sure I could just see my layout line and then used a sheet metal tool made by Vise-Grip to bend it with. I bent the metal a small amount, moved over a few inches, and then repeated this process. I did this until the bent surface was at approximately 45 degrees.
 

 

 

Next I used my soft-face hammer to finish the bend to 90 degrees. I did this for all four sides.
 

 

 
I left the bent edge slightly long and then trimmed it to length after all the bending. This way I was sure it would fit correctly.
 

 

 
Good clean bend with some nice fitting corners.
 

 

 
The two corners that sit against the chair frame needed to have a small amount of clearance because of some weld.
 

 

 
I ground the weld a small amount and now the step fits just right.
 

 

 
I'll be using these plastic caps to cover the open square tubing in four spots, two at the food rest and two at the top of the chair.
 

 

 
Here you can see the foot step is installed along with the two end caps. If you look close you can see I used two screws per side to hold the sheet metal to the plywood.
 

 

 
Here is a better look at some of the screws. And at this point the foot step is finished.
 

 
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