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Discover The Manual BAR FOLDER: Unleash This Tools Power (Folding Sheet Metal Easily!)

I spent most of my 37-year career in sheet metal working in the field. The tool that my coworkers carried the least but borrowed the most, was my Bar Folder. Bar folders are invaluable for turning flanges, folding hems and other types of bends. This is also the best DIY sheet metal bending tool.



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DIY Project Involving Sheet Metal? Bar Folder Is A Sheet Metal Folding Tool That Produces Good Results!


Man holding a Bar Folder metal bending tool and miscellaneous sheet metal tools sitting on a bench. There is also a image of a commercial full size metal bending brake.
Basic Sheet Metal Tools And A Commercial Bending Brake

When working on various projects, a DIY sheet metal part can often be the perfect solution. Being able to shape basic sheet metal forms in your own garage opens up opportunities for enhancement and creativity. You don't necessarily need a large Metal Bending Brake for this task. Instead, a handy tool like a Bar Folder or Sheet Metal Folding Tool can help you produce precise bends of high quality right at home.


Links To Purchase These Tools At End Of Article

A variety of sheet metal tools sitting on a bench. Included are hand shears, bar folder, pipe crimpers, adjustable scratching tool, vise grip hand seamer and sheet metal hammer.
Basic Sheet Metal Tools That Open Lots Of Possibilities

An Excellent Assortment of Tools Providing DIYers with Countless Options for Shaping Sheet Metal


See These Tools On Amazon (Affiliate Links - Learn more)



 

Sheet Metal Is Identified By Type Of Metal And Gauge.


 


Man is holding bar folder
Simple And Powerful - Crisp Bends In Sheet Metal

A Bar Folder Is A Simple Sheet Metal Tool That Is Extruded Or Constructed Of Sheet Metal


The bar folder in this photo is extruded. There is a solid center that gives it strength. There are pockets on either side that receive the sheet metal and hold it so it can be folded. There is a 3/8" side and a 1" side. Custom Bar folders are also commonly fabricated at shops by sandwiching a flat bar of the desired thickness in between 2 other pieces of metal and spot welding them together. Whatever depth of the pocket is required can be created. Shop made folders are usually heavy duty and often used for folding flanges on Metal Roof Panels.


Man sitting at bench holding bar folder and piece of sheet metal. There are sheet metal shears and vise grip hand seamers sitting on the bench.
Use The Bar Folder To Establish Bend Line

DIY Metal Working Tips And Tricks: A Bar Folder And Some Basic Sheet Metal Bending Techniques To Make Crisp Bends

For beginners, a bar folder is a straightforward tool that could be the most suitable for bending sheet metal. There are a few easy techniques to achieve sharp bends.



Man is using snips to cut a small notch in sheet metal. The notch will allow the metal to be bent at 90 degrees without rounding the edge of the metal.
Relief Cut To Help Make A Tight Bend

Relief Cuts Allow for Crisp Bends: Avoid Rounding The Edges Of The Metal

To mark the sheet metal, slide the bar folder over it and make a mark on both sides. Next, remove the bar folder and use a set of metal snips to create a small cut in the sheet metal. This cut will prevent the edges from rounding when you bend the metal.



Man is using a bar folder to bend sheet metal on a bench.
Hold The Bar Folder In Tight While Bending

How To Achieve A Good Bend With The Bar Folder Metal Folding Tool


Select the appropriate side of the bar folder according to the desired depth. Gently position the tool over the metal and secure it firmly in place before bending the metal. Once an initial crease is established, continue bending until the desired angle is reached.


 

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I made a few 90 degree bends in several pieces of metal.

A bench has a 24" bar folder sitting on it. A man is holding a vise grip hand seamer and piece of galvanize metal with 1" 90 Degree bend sitting behind bench.
Tuning Up A 90 Degree Bend With Vise Grip Hand Seamers

Hand Seamers like these Vise Grips work very well for tuning up the metal and getting the bend even.


I fabricated a bracket to hold my Winch Electrical Disconnect in both of my Jeeps. You can see more cutting and bending of sheet metal. Click here to see that video.



For more DIY Sheet Metal Fabrication see this video where I make a stainless steel license plate bracket. Click Here.


How Do I Cut Sheet Metal At Home?


I use a unishear which is a power tool that allows for straight cuts. This is a expensive tool that homeowners are not likely to have.


Alternatives For Cutting Metal


Snips like the 2 pictured above are a cheaper alternative to a expensive power tool like a Unishear of a set of Double Cut Shears. They are still very good at cutting lighter gauges of sheet metal.



Spiral ductwork and AC units hanging from a ceiling.
Sheet Metal Is Used To Make Ductwork

Every DIYer can benefit from having the bar folder metal folding tool in their garage. With a few tricks up your sleeve, you can create various parts for household projects. Pair it with the tools mentioned in this article to craft any shapes you can imagine.


Merch Section


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Amazon Shopping

✅ -  Channel Lock Pliers. (Amazon)

✅ -  Wiss Mini Bulldog Snips (Amazon)

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✅ -Variety Of Sheet Metal Folding Tools (eBay)



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Stacked Zarges Aluminum Cases sitting next to a Jeep Gladiator.
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As a Amazon Affiliate and Ebay Partner I receive a commission if you use my links to make a qualifying purchase. It does not raise the price you pay.


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