Edge Roller

[Wayne G. O'Shea]

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Clay, you can make a simple edge roller for about $5 from a piece of 1" x
1/4" (or 3/16") rectangular steel bar stock and two steel 1" (outside
diameter) roller bearings (or similar size). The roller bearings should have
a 1/4" roller width and a 3/16th I.D. Drill and tap the bar stock at one end
for 3/16th cap screws at a distance to leave about .025 between the rollers
for sheet .025" and down. I also have one with the rollers about .050 apart
for .040 and .032, but it rarely gets used. Leave enough bar stock above the
bearings so you can wrap your whole hand around the bar stock to get a good
grip on it. My homemade edge rollers work better than ANY of the ones I
bought from ATS and similar supply houses!

Practice on some scrap until you get used to holding even pressure to get a
smooth edge, otherwise you will put a real wave in the parts!

Regards,
Wayne G. O'Shea
www.irishfield.on.ca

----- Original Message -----
From: "Clay Smith" <cbsmith@nf.sympatico.ca>
To: " (Murphy Rebel Builders List)" <murphy-rebel@dcsol.com>
Sent: Sunday, February 11, 2001 3:48 PM
Subject: Re: Skylights

Thanks for the feedback. I'll check with the factory on Monday before
cutting. I was just hoping for another inch or 2 of width, and I would
still like to be able to use the factory headliner. Yes, I do remember
something about rounding the edge downward ... that makes good sense.
Was there some info posted a while back on making an edge tool?
Something about using shower door rollers, I think.
Also, I want to thank everybody for often including those encouraging
words like "keep at it, it's worth it" at the end of their message.
Those words certainly don't go unnoticed when your at my stage with
still so much to do. Thanks again!

Clay

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[Clay Smith]

I could only find smaller diameter (5/8") roller bearings around the house yesterday ...
but an 1 1/2 hour later, which included the time to make the tool and practise with a
scrap piece of metal, I was making nice round edges on my forward skylight. The roller
tool worked perfectly! Thanks again Wayne.


"Wayne G. O'Shea" wrote:

Clay, you can make a simple edge roller for about $5 from a piece of 1" x
1/4" (or 3/16") rectangular steel bar stock and two steel 1" (outside
diameter) roller bearings (or similar size). The roller bearings should have
a 1/4" roller width and a 3/16th I.D. Drill and tap the bar stock at one end
for 3/16th cap screws at a distance to leave about .025 between the rollers
for sheet .025" and down. I also have one with the rollers about .050 apart
for .040 and .032, but it rarely gets used. Leave enough bar stock above the
bearings so you can wrap your whole hand around the bar stock to get a good
grip on it. My homemade edge rollers work better than ANY of the ones I
bought from ATS and similar supply houses!

Practice on some scrap until you get used to holding even pressure to get a
smooth edge, otherwise you will put a real wave in the parts!

Regards,
Wayne G. O'Shea
www.irishfield.on.ca

----- Original Message -----
From: "Clay Smith" <cbsmith@nf.sympatico.ca>
To: " (Murphy Rebel Builders List)" <murphy-rebel@dcsol.com>
Sent: Sunday, February 11, 2001 3:48 PM
Subject: Re: Skylights

Thanks for the feedback. I'll check with the factory on Monday before
cutting. I was just hoping for another inch or 2 of width, and I would
still like to be able to use the factory headliner. Yes, I do remember
something about rounding the edge downward ... that makes good sense.
Was there some info posted a while back on making an edge tool?
Something about using shower door rollers, I think.
Also, I want to thank everybody for often including those encouraging
words like "keep at it, it's worth it" at the end of their message.
Those words certainly don't go unnoticed when your at my stage with
still so much to do. Thanks again!

Clay

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[rebel]

When do you use an edge rolling tool? Do I need one right away?
Thanks
Jesse




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[Wayne G. O'Shea]

You can build the entire airplane without it Jesse. It just won't look as
nice!

My personal airplane had no edges rolled on most stuff, but now I roll every
panels edge when I build... as it makes for a much nicer look and the other
plus side is that it gives a nice tight edge to help with keeping water out
and generally allows for the top coat paint to cover the gap and seal the
airplane.

You can easily make your own roller from a piece of 1/4" x 1" steel plate
about 6" long and two 1" diameter roller bearings. Drill and tap for cap
screws/bolts at the bearing diameter + about .032. I have another one with
about .050 gap, but rarely use it. I have found these homemade rollers work
better than any of the three commercial units that I have bought since
making my own.

Practice the "art" of edge rolling on some scraps to get a "handle" on hand
postioning and pressure requirements to make a nice edge.

Cheers,
Wayne

----- Original Message -----
From: <rebel@dcsol.com>
To: <rebel-builders@dcsol.com>
Sent: Saturday, June 12, 2004 11:29 PM
Subject: Edge roller

When do you use an edge rolling tool? Do I need one right away?
Thanks
Jesse




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[Jesse Jenks]

Thanks Wayne,
Do you use it to "bend" the edge over slightly on a panel, or are you just
decreasing it's thickness at the edge? Do you use it on all edges, butt
joints and laps? Sorry, my sheet metal book doesn't address this.
Do you "twist" the tool in order to press the bearings against the panel
edge? If so, could you just make one size and use it on all thicknesses?
Does the thickness of the bearings matter?
Jesse

You can build the entire airplane without it Jesse. It just won't look as
nice!

My personal airplane had no edges rolled on most stuff, but now I roll
every
panels edge when I build... as it makes for a much nicer look and the other
plus side is that it gives a nice tight edge to help with keeping water out
and generally allows for the top coat paint to cover the gap and seal the
airplane.

You can easily make your own roller from a piece of 1/4" x 1" steel plate
about 6" long and two 1" diameter roller bearings. Drill and tap for cap
screws/bolts at the bearing diameter + about .032. I have another one with
about .050 gap, but rarely use it. I have found these homemade rollers work
better than any of the three commercial units that I have bought since
making my own.

Practice the "art" of edge rolling on some scraps to get a "handle" on hand
postioning and pressure requirements to make a nice edge.

Cheers,
Wayne

----- Original Message -----
From: <rebel@dcsol.com>
To: <rebel-builders@dcsol.com>
Sent: Saturday, June 12, 2004 11:29 PM
Subject: Edge roller

When do you use an edge rolling tool? Do I need one right away?
Thanks
Jesse




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[Wayne G. O'Shea]

Jesse, once you get good at it you can hold the panel just about any way you
want, but I suggest to start out hold the panel tight against the table with
the edge hanging off. Hold the edging tool with the handle against the palm
of your hand with your thumb only over the the roller side of the handle.
Then roll the edger down the sheet working towards you while exerting a
small amount of outward pressure with your thumb. Don't stop mid sheet...but
roll it the complete length in one stroke. If it's not over enough then roll
it down again until you get what you want. The idea here is to bend the edge
over slightly so when the rivets pull the sheet tight it will give a nice
tight fit of the sheet against the sheet below it. This edging can also be
done in a brake, but only on straight cuts. I just put 1/4" into the brake
and clamp, and this generally gives enough of a "kick" to put the edge over.

If you make the gap too large between the bearings/rollers then they will be
running on their edges instead of flats and won't do as nice of a job.

Just went out to the shop and comfirmed that the bearings I use are approx
1/4" wide. They are NSK 626Z's and have an OD of 3/4" and ID of 1/4".

Wayne

----- Original Message -----
From: "Jesse Jenks" <jessejenks@hotmail.com>
To: <rebel-builders@dcsol.com>
Sent: Sunday, June 13, 2004 4:28 PM
Subject: Re: Edge roller

Thanks Wayne,
Do you use it to "bend" the edge over slightly on a panel, or are you just
decreasing it's thickness at the edge? Do you use it on all edges, butt
joints and laps? Sorry, my sheet metal book doesn't address this.
Do you "twist" the tool in order to press the bearings against the panel
edge? If so, could you just make one size and use it on all thicknesses?
Does the thickness of the bearings matter?
Jesse

You can build the entire airplane without it Jesse. It just won't look as
nice!

My personal airplane had no edges rolled on most stuff, but now I roll
every
panels edge when I build... as it makes for a much nicer look and the

other

plus side is that it gives a nice tight edge to help with keeping water

out

and generally allows for the top coat paint to cover the gap and seal the
airplane.

You can easily make your own roller from a piece of 1/4" x 1" steel plate
about 6" long and two 1" diameter roller bearings. Drill and tap for cap
screws/bolts at the bearing diameter + about .032. I have another one

with

about .050 gap, but rarely use it. I have found these homemade rollers

work

better than any of the three commercial units that I have bought since
making my own.

Practice the "art" of edge rolling on some scraps to get a "handle" on

hand

postioning and pressure requirements to make a nice edge.

Cheers,
Wayne

----- Original Message -----
From: <rebel@dcsol.com>
To: <rebel-builders@dcsol.com>
Sent: Saturday, June 12, 2004 11:29 PM
Subject: Edge roller

When do you use an edge rolling tool? Do I need one right away?
Thanks
Jesse




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[Jesse Jenks]

Thanks again,
I understand the concept now.
Jesse

From: "Wayne G. O'Shea" <oifa@irishfield.on.ca>
Reply-To: <rebel-builders@dcsol.com>
To: rebel-builders@dcsol.com
Subject: Re: Edge roller
Date: Sun, 13 Jun 2004 19:07:48 -0400

Jesse, once you get good at it you can hold the panel just about any way
you
want, but I suggest to start out hold the panel tight against the table
with
the edge hanging off. Hold the edging tool with the handle against the palm
of your hand with your thumb only over the the roller side of the handle.
Then roll the edger down the sheet working towards you while exerting a
small amount of outward pressure with your thumb. Don't stop mid
sheet...but
roll it the complete length in one stroke. If it's not over enough then
roll
it down again until you get what you want. The idea here is to bend the
edge
over slightly so when the rivets pull the sheet tight it will give a nice
tight fit of the sheet against the sheet below it. This edging can also be
done in a brake, but only on straight cuts. I just put 1/4" into the brake
and clamp, and this generally gives enough of a "kick" to put the edge
over.

If you make the gap too large between the bearings/rollers then they will
be
running on their edges instead of flats and won't do as nice of a job.

Just went out to the shop and comfirmed that the bearings I use are approx
1/4" wide. They are NSK 626Z's and have an OD of 3/4" and ID of 1/4".

Wayne

----- Original Message -----
From: "Jesse Jenks" <jessejenks@hotmail.com>
To: <rebel-builders@dcsol.com>
Sent: Sunday, June 13, 2004 4:28 PM
Subject: Re: Edge roller

Thanks Wayne,
Do you use it to "bend" the edge over slightly on a panel, or are you

just

decreasing it's thickness at the edge? Do you use it on all edges, butt
joints and laps? Sorry, my sheet metal book doesn't address this.
Do you "twist" the tool in order to press the bearings against the panel
edge? If so, could you just make one size and use it on all thicknesses?
Does the thickness of the bearings matter?
Jesse

You can build the entire airplane without it Jesse. It just won't look

as

nice!

My personal airplane had no edges rolled on most stuff, but now I roll
every
panels edge when I build... as it makes for a much nicer look and the

other

plus side is that it gives a nice tight edge to help with keeping water

out

and generally allows for the top coat paint to cover the gap and seal

the

airplane.

You can easily make your own roller from a piece of 1/4" x 1" steel

plate

about 6" long and two 1" diameter roller bearings. Drill and tap for

cap

screws/bolts at the bearing diameter + about .032. I have another one

with

about .050 gap, but rarely use it. I have found these homemade rollers

work

better than any of the three commercial units that I have bought since
making my own.

Practice the "art" of edge rolling on some scraps to get a "handle" on

hand

postioning and pressure requirements to make a nice edge.

Cheers,
Wayne

----- Original Message -----
From: <rebel@dcsol.com>
To: <rebel-builders@dcsol.com>
Sent: Saturday, June 12, 2004 11:29 PM
Subject: Edge roller



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[rognal]

I've used a "slot cut in a stick" to roll the inside radius edges of the
skylight openings where my commercially made edge roller wouldn't fit.
Actually it was a (hacksaw) slot cut in a piece of delrin. It worked well.
Work slowly and make several passes if needed, until you get what you want.

Roger Hoffman #687R
Eugene, OR USA!



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[Drew Dalgleish]

At 08:32 AM 6/14/2004 -0800, you wrote:

I've used a "slot cut in a stick" to roll the inside radius edges of the
skylight openings where my commercially made edge roller wouldn't fit.
Actually it was a (hacksaw) slot cut in a piece of delrin. It worked well.
Work slowly and make several passes if needed, until you get what you want.

Roger Hoffman #687R
Eugene, OR USA!

Delrin wow that's pretty fancy I use an old peice of broom handle.
Drew





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[Bill Delcambre]

Man, ya just gotta love this group!

I was impressed by Wayne's rendition of design and use of the edge roller.
Seemed that Roger was on to a great idea, making such from plastic. Now,
Drew tells us of his design, using 'scrap' materials. Gettin better all the
time!
If we pool resources, I'd bet we could beat Rutan to the X-Prize.

Bill

----- Original Message -----
From: "Drew Dalgleish" <drewjan@cabletv.on.ca>
To: <rebel-builders@dcsol.com>
Sent: Monday, June 14, 2004 3:13 PM
Subject: Re: Edge Roller

At 08:32 AM 6/14/2004 -0800, you wrote:

I've used a "slot cut in a stick" to roll the inside radius edges of the
skylight openings where my commercially made edge roller wouldn't fit.
Actually it was a (hacksaw) slot cut in a piece of delrin. It worked

well.

Work slowly and make several passes if needed, until you get what you

want.

Roger Hoffman #687R
Eugene, OR USA!

Delrin wow that's pretty fancy I use an old peice of broom handle.
Drew





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