How to make a flat corner for a cable tray

To create a flat corner in a cable tray, you need to mark, cut, file, and bend the tray carefully, then reinforce it with a gusset for stability.Step-by-Step Process1. Mark the Tray: Begin by marking the center line and the area where the bend will occur. Measure the width of the tray and determine how much of the tray lip needs to be removed. Typically, for a 90° bend, remove about 2¾ of the tray width, splitting this evenly on either side of the center line (construction step A) . 2. Remove the Tray Lip: Use a hand grinder or file to remove the marked lip sections. Ensure you wear proper protective equipment when using a grinder to avoid injury (step B and C) . 3. Cut the Center Line: Carefully cut down the center line of the tray. Take care not to let the tray fall open, as this can damage the tray (step D) . 4. Flatten the Lip: Use a blunt object to flatten the tray lip at the bend point. This prepares the tray for a smooth fold (step E) . 5. Bend the Tray: Bend the tray to the desired angle, typically 90°, and bolt the two parts together to maintain the shape (step F) . 6. Add a Gusset: Measure the distance between the internal edges of the bend. Cut a piece of tray to this size, remove one lip completely, and bolt it to the bend to reinforce the corner (step G and H) .Calculating Cut Sizes for Different AnglesFor angles other than 90°, you can calculate the cut size using the tray width and desired angle. For example, for a 45° bend in a 100 mm tray, measure from the center line and mark half the angle on each side. File or cut the lip accordingly, then fold so the cuts overlap . This method can be applied to any tray width and angle.Tips and SafetyAlways wear protective gloves, goggles, and a mask when cutting or grinding metal trays.Test the bend on cardboard or scrap material first to ensure accuracy.For adjustable corners, you can use pre-made adjustable corner pieces that fit inside the tray and are secured with screws, allowing angles from 0° to 75° without cutting . By following these steps, you can create precise flat corners in cable trays for clean and safe cable routing.