DIY 90-degree cable tray

A 90-degree cable tray bend can be made by marking, cutting, flattening, and bending the tray, then securing it with a gusset or bolts.Step-by-Step Guide1. Mark the Tray: Begin by accurately marking the location of the 90-degree bend on the cable tray. Measure the width of the tray and mark the center line where the bend will occur. Also, mark the areas for cutting the tray lips on either side of the center line to allow a flush bend . 2. Remove Tray Lips: The tray lip to be removed is typically 2/3 to 3/4 of the tray width, split evenly on both sides. Use a small hand grinder or file to carefully remove the lip, ensuring proper protective equipment is worn . 3. Cut the Center Line: Cut down the center line of the tray to facilitate bending. Take care not to let the tray fall open or become damaged during this step . 4. Flatten the Tray Lip: Use a blunt object to flatten the tray lip at the bend point. This prepares the tray for a clean 90-degree bend . 5. Bend the Tray: Carefully bend the tray to a 90-degree angle. Ensure the bend is precise and the edges are aligned. For larger trays, a bending tool or truncheon may be used to apply even pressure . 6. Secure the Bend: Measure the distance between the internal edges of the bend to create a gusset. Cut a piece of tray to this size, remove one lip completely, and bolt it to the 90-degree bend to reinforce the structure . 7. Optional Vertical or Prefabricated Bends: For vertical or adjustable bends, prefabricated elbow joints can be inserted into the tray and secured with screws, allowing a range of -90° to +90° .Tools and SafetyHand grinder or fileMeasuring tape and markerBlunt object for flatteningBolts and gusset materialProtective gloves, goggles, and hearing protection Following these steps ensures a clean, structurally sound 90-degree bend suitable for cable management in electrical installations .