How about cutting a hole in a piece of ply wood the shape you want then lay and clamp the alloy on i t. Electric Pressure Washers Petrol & Diesel Driven Pressure Washers Hot Pressure Washers Pressure Washer Accessories Detergents, Chemicals and Algicides Pressure Washer Spares Hoses & Accessories Only really need it for one job, but funds are to tight to cough up that sort of money for something that I may never use again. You should be able to achieve this using simple male/female wooden forms that you can clamp the sheet between. For making these a wood router would I suppose you could make up a pair of jaws and weld them to a cheapo set of Mole grips? Personally I'd advise against getting one.

An edge Joggler (or Joddler / Flanger as it also called) allows you to produce perfect flush welded lap joints every time with the minimum of effort Ah Mike, a man after my own heart. Very simple, no expensive tools needed, clamp it up an tap it down and the beauty of this method is that you can The Joggler jaws sets down a 12mm wide step along the panel edge in mild steel up to 1mm (18g). The long handles make it easy to use. This robust tool brings professional quality work to your fingertips with machine accuracy. Good advice from the above. For a small hole a Joddler would not work but a simple press tool certainly would. If you have a number of holes all the be a useful tool to own, but not completely necessary as you can build up forms from multiple thin sheets of material.I may be wrong but i think he want's a inspection hatch type hole say like over the foot peddles say 200mm x 300mm and a flat panel fitting in It is easy to put a stepped flange round a radius but I'm not sure if the flange would be wide enough for a Dzus fixing. I used M5 rivnuts. Just a few more details of the tool I used. It's called a Rolastep and available from LB Restorations. Link: Precision jaws make 10mm flange on 18-20 gauge mild steel or aluminium sheet and provide smooth, flush joint between panels. Air Compressor Filters Accessories & Consumables Air Tools and Accessories Oils & Lubricants Low Noise Compressors

The Frost Joddler is a simple hand tool particularly useful for vehicle body and sheet metal repairs that involve joining two pieces of metal sheet together.Just got this 18to 20 gauge 1 mm to 1.2 but the jaws are only 1 mm deep so no chance of joggle in 18 gauge not happy Electric Heater Accessories Gas Cylinder Storage Gas Heater Accessories Propane/Butane Hoses and Regulators same to do, it's might be worth making up as tool. Try to ensure that the aluminium is clamped top and bottom so that the panel will not be

hammered the shape into the panel. It's best to go gently and take a few passes to get the folds fully formed or you risk ripping the metal. have a guide to Joggling or can you recommend a tool? I would like the corners to be radiused, how do you do that?Let your plans be dark and as impenetratable as night, and when you move, fall like a thunderbolt.”

I bought mine but discovered that it didn't make very neat joints, so I always butt weld now. The punch is useful however. Submersible Pumps - Fountain & Pond Miscellaneous and Transfer Pumps Pump Accessories Pump Controllers & Switches Hose Hose Clips Couplers, Valves & Filters Washdown Pump KitsI want to joggle the edge of a hole in an aluminum sheet so that I can fit a flush fitting panel held in with dutz or simpler fasteners. does any one