Johnson Bros. Metal Forming Co.

Parts are produced to order and stock reserve only kept for large blanket order shipping releases. Existing samples may or may not be available. Prototypes for large orders are feasible.

Inline Press Fabrications of: Holes, Slots, Notching, Tabs, Shear Forms, End Fabricating, Cut to Length, Pointing & Staking, Roll Edged Ends, Flattened Ends, and more. Secondary Fabricating: End Fabricating, Roll Edge Ends, Bent and Flattened Ends, Cuttouts, and more. Telescoping Sets Available for Lock Seam Tubes Lock Seams are Tight and will not break open when bent, or flattened, or twisted. Other Custom Special Shapes are possible, along with Finned or Flanged Seams. Strippable PVC Protection can be added to lock seam tubes for Protecting Decorative Finishes. Double Sided Adhesive Tape and Other Materials can be Applied Inline during forming. Can be economical with Thin Wall, with Prefinishing andor Inline Fabricating. Thicker Wall Thicknesses can be provided with Special Tooling required. Ends of lock seam tubes can be Clean Cut, Dimple Free, using Inline Prenotching Tooling. Not Air or Water Pressure Holding, Collapses when Bent Steel Should be Prefinished. Raw Finished Steel is not as economical to Lock Seam Tubes

Other ways to produce flanges that we do not do, would be: buying mill hot rolled or extruded angle in straight lengths, then bending them one at a time in a 3 roll bending unit and trimming and welding the ends, whereas our forming is a continuous process with flange angle rings coming out as spirals before cutting to length. Another production method is casting. This process gives a seamless flange with no end welding or cutting to length. Flanges are then machined many times to close tolerances afterwards. This is an expensive method but gives high quality parts. Our company does not carry flanges in stock unless they are part of a blanket purchase order.

C Channel & Box Channel thicknesses vary from .003" thick up to .150" thick. On 14 & 12 hard aluminum, Aluminum C Channel & Aluminum Box Channel thicknesses can reach up to .250" thick. Many different decorative pre-coated metals are generally not recommended when more than .030" thickness is required unless larger than normal corner radii can be used. Some coatings can be used, however, up to .125" thick such as a pre-finished Hot Dip Galvanized coating. Box Channel & C-Channel Lengths may be from 3" thru 40 feet long with close tolerances. Many different lengths can be put on one purchase order.

Johnson Bros U-Channel & J-Channel thicknesses can range from .003" thick up to .150" thick. On 14 & 12 hard Aluminum, thicknesses may be as much as .250" thick. Many different decorative pre-coated metals are not generally recommended when more than .030" thickness is required unless larger than normal corner radii can be used. Some coatings can be used, however, up to .125" thick such as a pre-finished Hot Dip Galvanized coating. Standard Tooling is available for most sizes. Our Capacities on U Channels and J Channels are: Using up to .075" maximum thickness, Legs can be up to 5.5" O.D. High and Web widths can be up to 19" O.D. wide. Using up to .156" maximum thickness, Legs can be up to 4" O.D. high and Web widths can be up to 14" O.D. wide. Aluminum U Channels & Aluminum J Channels will have higher maximum thicknesses.

Roll Formed Metal Angles are the most basic of all Roll Formed Profiles. Tooling required is simple, and inexpensive to setup. For 90 degree leg angles, tooling is always existing, up to 4" O.D. leg height using up to a 316" maximum thickness, and up to a 9" O.D. leg height using a .075" maximum thickness. Aluminum maximum thicknesses can be thicker than 316" and .075". Legs can be as short as .090" tall, though, very short legs can involve die modifications for trapping the legs in place. On thinner materials, hemmed legs can also be added with existing tooling. Most Angles have equal legs but we get requests from many customers for unequal leg angles also called L's. There are Angles with more than a 90 degree bend called Vee's. There are angles with less than a 90 degree bend leaving the legs more open than 90 degrees. A 90 degree bend is by far the most common for an Angle. Johnson Bros. has expertise at forming angles to accurate finished and random lengths with low cost at high speed. This is accomplished with cutoff die boosts and accelerators on our pneumatic and hydraulic presses. We specialize at producing Angles that are thinner or the same thicknesses but have unequal legs that are not available as a Hot Rolled Mill Angle, Extrusions or as Angle Irons. On thicker materials it is always good to remember that unlike hot rolled mill angles which have a sharper outside corner and a large inside corner, Roll Formed Angles have a larger outside corner radius and a sharper inside corner radius. As with all roll forming, the outside radius is the total of the inside corner plus the metal thickness. Material thicknesses can be from .005" through .188" thick. Our angles come in many types of metal including steel, aluminum, brass, and stainless steel.