1. Arduino Switch Tunnel Bending
Best to use thin permanent marker for the fold lines. Note the radius bend allowance, close lines. See drawing.
Greg Moore 2012 Folding the switch tunnel

2. Arduino Switch Tunnel Bending
The bends will be done from Left to Right. Start with the wing, note the bend radius allowance, and setback.
Greg Moore 2012 Folding the switch tunnel

3. Arduino Switch Tunnel Bending
90 Degrees to each bend.
Greg Moore 2012 Folding the switch tunnel

4. Arduino Switch Tunnel Bending
It may be an idea to put the bend lines on both sides of the chassis, as some bends are in the opposite direction.
Greg Moore 2012 Folding the switch tunnel

5. Arduino Switch Tunnel Bending
The next bend here is bent opposite direction, so the bend lines on each face are convenient.
Greg Moore 2012 Folding the switch tunnel

6. Arduino Switch Tunnel Bending
Slowly, the bends start to form the tunnel shape for the switchbox.
Greg Moore 2012 Folding the switch tunnel

7. Arduino Switch Tunnel Bending
The metal is turned around again to allow the downward bend as shown here.
Greg Moore 2012 Folding the switch tunnel

8. Arduino Switch Tunnel Bending
Towards the end of the bending on the pan brake bender, just enough space to clear the bending die.
Greg Moore 2012 Folding the switch tunnel

9. Arduino Switch Tunnel Bending
Unfortunately, the last bend cannot be bent in the pan bender, nor can it be bent in the magnabend. Other method need to be employed.
Greg Moore 2012 Folding the switch tunnel

10. Arduino Switch Tunnel Bending
Study this photo and it can be shown the switch tunnel shape does not allow the last flat wing to be bent in the pan bender.
Greg Moore 2012 Folding the switch tunnel

11. Arduino Switch Tunnel Bending
An alternate way to bend is to use the vice on the bench. Use the bend radius lines when fitting the bracket.
Greg Moore 2012 Folding the switch tunnel

12. Arduino Switch Tunnel Bending
Using a dolly inside the bracket, and using a lot of force concentrated over the corner will allow the bend to be made.
Greg Moore 2012 Folding the switch tunnel

13. Arduino Switch Tunnel Bending
The finished bend in the vice. If adequate pressure applied with the steel, the bend radius not excessive.
Greg Moore 2012 Folding the switch tunnel

14. Arduino Switch Tunnel Bending
The finished bend in the vice. If adequate pressure applied with the steel, the bend radius not excessive.
Greg Moore 2012 Folding the switch tunnel

15. Arduino Switch Tunnel Bending
The completed tunnel assembly before drilling for the switches and LED’s
Greg Moore 2012 Folding the switch tunnel

16. Arduino Switch Tunnel Bending
If the bending steps are followed, you will get a good product with clean bends as shown here.
Greg Moore 2012 Folding the switch tunnel

17. Arduino Switch Tunnel Bending
Please use the Drawing as provided to mark out the switch tunnel.
Greg Moore 2012 Folding the switch tunnel

18. Arduino Switch Tunnel Bending
The End
Greg Moore 2012 Folding the switch tunnel