I spent a lot of time measuring the old box and laying out the bend lines and bead lines on the new sheet. Take special note of the word "INSIDE" written on the piece. This is placed on all parts due to my tendency to make "reverse" parts unless I am told otherwise.
The roll was made by clamping the sheet to the table with a piece of heavy wall tubing. This roll is slightly more than 90 degrees. The radius on the original is approx. 2 inches. Without dedicated equipment, it is difficult to exactly duplicate this. So you have to be prepared to adjust your next brake lines as you go. In this case, I had to make the bottom flange a bit bigger than I originally planned. The bright side is that it is easier to cut off excess than add on!
A little bit of straightening and shrinking and the part is ready for the bead roller. I now have to convince my wife to come to the garage and turn the handle while I feed the part. Check back soon.
