Routing – Optional Method for Angular Bends

Successful angular bends require a “V” groove cut completely across panel through liner and core. Refer to Figure 3-2B. These grooves can be made using the following professional or industrial type equipment:

Router with special shaped carbide-tipped bit.

Circular saw with special carbide-tipped blade with profile to provide “V” groove per Figure 3-2B.

     Figure 3-2B: Panel With V-Groove

     Figure 3-3: Routed Panel With Angular Bends

Routing of the Formacore panel requires using a router or circular saw in conjunction with edge guides and securely clamping the Formacore panels in-place with face side down. This allows the router or saw to travel across the liner surface of the Formacore panel. A preferred way to achieve a 0.015” depth of routed groove is to gauge off of the 0.040” face of the panel.

The edge of the routed panel can be bent using an aluminum extrusion or similar rigid instrument (see Figure 3-4). Bending the full length of the Formacore panel gives a uniform bend. Long panels may require more than one person.

Panel edges may also be bent using extrusions shorter than the length of the panel or by using hand held clamps. This generally does not produce a truly uniform bend.

     Figure 3-4: Grip For Bending Panel

The groove shown in Figures 3-2A & 3-2B provides minimum radius for bending the Formacore panel. When more rounded bends are desired, this requires that a wider groove be cut in the Formacore panels as shown in Figure 3-5. A guide bar is required to obtain a smooth bend radius.

     Figure 3-5: Routed Panel With Radius Bends