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The need for the larger break came out for the need to form 3 foot wide aluminum for fuel tank as the original break we made is only 2 feet wide. Going second time around thought was to make press rather then a break however to make a proper press it would be need for much heavier materials to make the press from, it would be naturally much heavier and additionally it would require sort of hydraulic pump for the press. The benefit of it would had been that it could handle much thicker material plus with different widths of blade it would be possible to make more complex part forming.

So being that the need was just to make fuel tank we had opted out to make a larger break. Improving on version 1, version 2.0 is 48.5" wide which will allow a 4 foot wide sheet to be easily fit into it. Not sure if this will ever be used but for the cost of making it vs. getting the aluminum sheets bent at fab shop to requirements will top the cost of  materials to make the break.
Not that the first version did not work but there are couple tings needed to be changed:
1) being that the new version is 48" wide, hinging needs to be changed.
2) the hinging on the smaller version was bit off and was only capable of bending to about 80'.
3) Working with 18ga sheet metal thickness of the material did not make much of a problem so there was no adjustments for it.
4) The base on original had no extensions so bending of full with 2 foot sheet was some times difficult

Started with 2x2x0.082" angle iron recycled from unused project, cut it down to 48.5". As this piece is going to be the base decided to strength it with additional 1.5x1.0x0.128 tube, however rather than using a good piece we decided to splice some old cutoffs to make up the length. Cut down 2 pieces of 0.75x1.5x0.096 old cut off into 8" lengths. The 48" tube was welded onto back of the L iron and the 2 shorter pieces where welded to the sides. Base extensions will be welded in later as to prevent bulkiness at current time.

The purchased hinges having back bent to them and to allow smooth movement that would not run on either base or bending arm need to have spacer welded on. We used scrap 0.120" tubes destant for scrap and cut out strips then welded them to the backs of the hinges which provide enough of a spacing so that the hinges pivot easily. With a flat piece clamped to top of the base then a hinge pressed against it and clammed to the base they where welded onto the base. The method proved to be very accurate as the hinges are pivoting at same straight line.

With the hinges welded to the base, next step is the folding ramp. Clamped short pieces of flat onto wider side of the 2x1 tube then placed the tube with flat edge onto the hinges and tack in place. Removed the clamps and flat pieces to make sure that it pivots smooth then welded it fully into the hinges. This makes the base and folding ramp a one piece.

Next what needs to be done is a support to hold down the L angle that will be holding material to the base and on which the material will be bent against. With the second piece of 1.5x1" piece, on the 1"  a number of holes are drilled  and tapped for 3/8" rod that will be used to push down and hold the L angle. Having the cross bar prepared and with a small 1x1 cutoffs used as spacers, the horizontal cross bar set back 0.25" from face was welded into place onto the 2 8" side pieces. Next the clamping L angle was placed in its location then a small 3/4" capped off square tubes where welded to it to provide a furthest possible resting position.

With the main bending assembly completed, a scrap 18" 2x4 tubes where welded to the back of the base part so that there will be a way in preventing the base from twisting. scrap small size tubes where welded to the front pivoting ramp giving a handle to use when bending

She does not look pretty but she has a way to clamp the material and a way to pivot and make a bent in the sheet.


NOTE:
After some work with the tool, bending 18ga hot rolled steel sheet is not too bad. However as this was build primarily 0.120" aluminum sheet for our fuel tank, the process of bending 48" wide sheet proved to be bit harder chore then expecting and bending steel sheet. First of all its the nature of aluminum and how it bends but also the extra thickness of the aluminum that proved to be much harder then expected. We had managed to bend it but knowing that it was that hard to do it it probably would had been better if we would have taken the sheet after marking it to local metal working shop and have it bent on press and most likely thats what we had done for next one.

 
 
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