I have a problem trying to get the correct amount of
relief in a box so that when formed up it's not binding.
The box is 6.0 x 6.0 with 1.0" ouside flanges. 11 ga hrs (.119).
First I tried making the box with a base,then edge flanges.
When unfolded it ends up about .105" to short for forming.
I should mention that I'm using .125" radius. If it was thinner
material this wouldn't be a problem. The second way I tried
extruding a blank to 1.0" ,shell it to .119" then rip the corners.
Add sheetmetal and when this unfolds it's also comes up short.
I'm using a .259 Bend allowance. Any thoughts on this for relief
cuts. I tried tear,rectangle, and obround which you'll see that they
don't work. I did try the 3rd way by creating a blank 6x6 converting
to sheetmetal with the .119" thickness and what edge flanges with
.010" gap. This when unfolded did come out correct but way to much
relief for welding. Closed corner doesn't work. Any suggestions ???
Still waiting from tech support.....