TAPCO TOOLS Windy SP Port-O-Brake User manual

Operations Manual
“Windy” SP Port-O-Brake
®
shown with optional
Tapco PRO-Coiler
®
and
Light Duty Folding Legs.
TABLE OF CONTENTS
Introduction.................................................. 2
Setup Instructions......................................... 3
Accessories.................................................... 4
Hints for Bending.......................................... 5
Examples of Common
Trim Shapes................................................... 6
Troubleshooting............................................ 7
Cleaning Locking and
Clamping Surface.......................................... 8
Replacing Stainless Edge............................... 9
Replacing Vinyl Strip ..................................... 9
Replacing Wedges....................................... 10
Replacing Hinges ........................................ 10
Replacing Shoe Castings ............................. 11
Windy Parts List .......................................... 12
All Tapco Tools are made under
one or more of the following U.S. Patents:
3,161,223 4,321,817 4,651,553 4,489,583
4,493,200 4,445,356 4,372,142 4,766,757
3,817,075 4,557,132 4,240,279 4,671,094
3,482,427 4,494,397 3,559,444 5,343,728
5,353,620 5,505,069
Other U.S. & Foreign Pats. Pend.
TapcoTools.com | [phone]

2
TapcoTools.com 800.521.8486
Congratulations on your purchase of a quality built Tapco "Windy" SP Port-O-
Brake®. With proper care and maintenance, your Port-O-Brake®will provide you
with many years of excellent service.
This booklet will outline in detail the simple steps to properly maintain your Port-
O-Brake®and the proper procedure to use should your
Port-O-Brake®need repair. By following our General Hints you can
prevent many costly repairs.
If you nd that your Port-O-Brake®needs a replacement part, it can be obtained by
contacting your local Tapco Tools distributor.
GENERAL HINTS
1. Clean your Port-O-Brake®at least once every 40 hours of use. Follow the fast
and easy procedure outlined on page 9.
2. Use a high quality cleaning solvent such as Gum-Out®or WD-40®.
3. Use only lightweight lubricants such as“3 in 1” Oil®, or 30 wt. oil. Note: Do not
use vasoline, axle grease, or graphite because they tend to “hold”dirt.
4. Use only clean shop rags that are free of dirt or metal chips.
5. Do not use your Brake around your saw table as the cuttings
may get between clamping members and cause excessive wear
or material scratching.
“WINDY”SP MATERIAL BENDING CAPACITIES
Soft Aluminum...................................................Up to .030
Hard Aluminum (Gutter Coil)........................Up to .022
Steel* .....................................................................Up to 29 ga
Galvanized Steel*..............................................Up to 29 ga
Copper Annealed..............................................Up to 12 oz
Copper Soft .........................................................Up to 24 oz
Vinyl........................................................................All standard
vinyl sidings
*Specications may vary with temper of material
For Your Records
Complete the information below and save with this manual for future reference.
Model and Serial Number Date and Place Purchased
Introduction

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1Remove Locking Handle and
Handle Grip from parts bag. Press
Grip over end of Locking Handle and
slide down until Grip is rmly seated.
Remove rest of parts from bag and
proceed to next step.
2Insert bottom end of Locking
Handle into the bottom Yoke on right
side of Port-O-Brake.®Align holes
and insert Yoke Pin. Align top hole in
Handle with holes in Locking Block of
Slide Bar and insert second Yoke Pin.
3Insert Cotter Pins through holes in
ends of both Yoke Pins. Bend one leg
of each cotter pin forward to secure
Yoke Pin.
1Insert the ends of the Lifting
Handle/Handle Plug Assembly up
through the holes in the bottom of
the Moving Hinge. Align holes in the
Handle Plugs with the holes located in
the face of the Moving Hinge.
2With holes aligned, insert screws
through Moving Hinge and into
Handle Plugs. Place washers over
ends of screws in back and tighten
with hex nuts. Handle can now be de-
tached from Handle Plugs by remov-
ing Faspins.
FACE OF
MOVING HINGE
ALIGN HOLES
AND INSERT
SCREWS
FASPIN
SCREW
FASPIN
LIFTING
HANDLE/
HANDLE PLUG
ASSEMBLY
MOVING HINGE
WASHER
HEX NUT
HANDLE PLUGS
BEND ONE LEG OF COTTER PIN
OUT AFTER PASSING THROUGH
YOKE PIN
Setup Instructions
COTTER PIN
Attaching the Locking Handle
Setting Up the Lifting Handle
YOKE PINS LOCKING
HANDLE
YOKE
LOCKING
BLOCK

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Accessories for the “Windy” SP Port-O-Brake®
Pro-Coiler™
The portable coil holder that
becomes an integral part of your
“Windy” SP Port-O-Brake®
• Keeps the coil o the ground and always
in front of you
• Helps ensure you get straight cuts all the time
• Helps increase production and eliminate waste
• Holds 24” wide by 100’ coil
Hooks on and detaches in seconds. Al-
lows you to roll out and cut coil squarely
to your exact length.
Change coils quickly by simply un-
hooking Roller Clip at one end and
inserting new coil.
Leg Tubes
Mounting Plate
U Clamp
Mounting Plate
Channel
Leg Plate
361/2”
Center of
Brake
3Set legs onto Brake with leg tubes near drilled
pilot holes. Place“U” clamps over leg tubes, align
holes and install sheet metal screws. Drill re-
maining holes through clamps and install screws.
Install screws also in mounting plates as shown.
1Position leg plates into
mounting plate channels,
align holes and install nuts
and bolts provided.
361/2”
361/2”
Drill
Drill
Drill
Drill
U Clamp
Mounting
Plate
Center of Brake
‰
2Invert Brake. From center of Brake,
measure outward along each rail
361/2” and drill one pilot hole in cen-
ter of each rail using an 11/64”drill bit.
Installing the Light Duty Folding Legs
Rail
361/2”
“Windy” SP Port-O-Brake®
with optional accessories:
Pro-Coiler and Light Duty
Folding Legs

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Traditional Bending Techniques
Helpful Hints for Trim Work 5. For some shapes you will be removing the piece and either
spinning it front to back or ipping it face up or face down to
make the next bend. Use proper care to avoid damaging the
piece especially on windy days.
6. Don’t t your trim parts too tight. This will complicate the joints
where parts overlap. A one inch (1") lap joint is enough to allow
for expansion and contraction. Trim should be lapped so that laps are facing
away from trac areas.
7. When face nailing try to nail the trim parts on an area that will
make the nails less conspicuous. Fasten at laps. Also when face
nailing, use just enough nails to secure trim; DO NOT DRIVE
NAILS TOO TIGHT or you will dimple the trim.
8. Remember,when designing shapes you are hanging a cover
over the wood parts, not laminating a skin-tight surface. This is
called “Floating Your Trim”. Allow for irregularities in the wood
because your formed trim shapes are straighter than the wood
trim moldings or boards you are covering.
9. With practice, you’ll learn to overbend or underbend certain
sections to achieve a pressure t of your trim parts which will,
in turn, require fewer nails and give your job a more nished
appearance.
10. Follow the suggested sequence of bends for the example given or
you may be “trapped” and unable to complete a shape. Tailor the
same steps to your own custom shapes.
1. Measure the total length of the particular trim area to be cov-
ered and divide by the length of your Brake to determine the
number and length of trim pieces needed.
2. Determine the dimensions of each section of the desired trim
shape by measuring that particular prole to be covered. As
an aid, make a pattern by bending a 1" strip of coil to get your
exact prole.
3. Transfer the dimensions in Hint #2 to each end of a piece of trim
coil by making a 1⁄4"slit in the metal with a pair of shears.These
marks now become the bending points and are visible from
either side. On longer lengths fold the coil over as shown and
snip both ends at once. This saves time and ensures accuracy.
4. Lock the pre-marked coil blank into the Brake with the cut marks
located directly under the outer edge of the Stainless Bending
Edge. Lock Brake. To cut o the coil with a razor knife, score the
metal against the Stainless Bending Edge. Now bend the metal up
and push back down by hand until the exposed section breaks o.
It may require 2 or 3 repetitions. When breaking material repeat-
edly, bending to just 45° will avoid rounding the edge.
1. This shape is basic to all other shapes made with the“Windy”SP
Port-O-Brake® . Take time to practice before you proceed with
other shapes.
2. To begin, cut o a piece of coil 4 inches wide by about one foot
long (as shown at right).
3. Place your tape measure on the coil and mark the coil with a
pencil at 3/4" and again at the 11/2" mark beyond that. Make sure
opposite sides are marked.
4. Now snip these marks as shown to the right so that they will
be visible on both sides of the coil (for some shapes you will be
turning your material both face up and face down).
5. Place sheet of coil into Brake with nished side down leaving
only rst set of 3/4" marks hanging out. (Generally, insert the
largest part of the material into the Brake rst.) Bend is at
this mark so lock your brake on these marks and bend 90°.
6. Unlock the Brake and slide the material to the second set of
marks . Bend 90° again to complete the shape.
Bending a Sample J-Channel
Siding
Pocket
Nailing Flange
Exposed
Trim
Covering
Material: Aluminum coil 4”
wide by the desired length
(For this example 12” long)
1. Numbers show the sequence of bends; thus
would be the rst bend and the second.
2. “Finish Side Up”indicates that the nished or exposed
side of the trim is to be put into the Brake Facing Up.
3. “Finish Side Down” indicates that the finished or
exposed side of the trim is to be put into the brake
facing down.
GENERAL INSTRUCTIONS FOR ALL EXAMPLES

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J-CHANNEL
Illustrated below are typical shapes used on common siding jobs which you can form with the “Windy” SP Port-O-Brake. The
numbers indicate the recommended sequence of bends. “Finish Side Up” indicates that the exposed or nish side of the
trim material is to be placed in the Brake facing up.
DRIP CAP/SILL/MULLION
BOX/DOOR CASING LINTEL
FASCIA BRICK FRIEZE
FRIEZE INSIDE CORNER
Finish
Side
Down
1 2
1
2
12
2
3
1
2
1
3
4
1
2
41
2
3
Finish Side Finish Side
Finish
Side
Down
Finish
Side
Down
Finish
Side
Up
Finish
Side
Down
Finish
Side
Down
34
Finish
Side
Up
Finish
Side
Up
Finish
Side
Down
Finish
Side
Up
Finish
Side
Down
Finish
Side
Down
Finish
Side
Down
Finish
Side
Up
Finish
Side
Up
Finish
Side
Down
Finish
Side
Up
Finish
Side
Down
Finish
Side
Up
Finish
Side
Down
Finish
Side
Down
Finish
Side
Down
Finish
Side
Down
Finish
Side
Up
5
Finish
Side
Down
Finish
Side
Up
Finish
Side
Up
Finish Side Finish Side
Finish Side Finish Side
Finish Side Finish Side
1
Finish
Side
Down
4
5
3
2
3
Examples of Common Trim Shapes

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MATERIAL SLIPPAGE
Material Slippage is caused by the Brake not locking properly or fully along the entire length.
To determine the need for Wedge Adjustment:
A. Cut paper into sheets approximately 2" x 6".
B. Insert paper into clamping position under each Shoe Casting.
C. Lock Brake
D. Try to remove paper while Brake is locked by lightly pulling on the paper.
If paper slips out easily, that particular Casting should be adjusted.
Solution:
A. Clean and lubricate Wedges, Sliding Bar, and Clamping Bar. (see page 9)
B. Tighten Fasteners for Hinges, Yoke, and Wedges.
C. Inspect Shoe Casting for damage due to dropping or other accidental abuse.
Replace if necessary (see page 12).
SCRATCHES OR MARRING OF MATERIAL
A. Do not use your Brake around your Saw Table as the cuttings may get
between clamping members and cause excessive wear or material scratching.
B. Wipe jaws clean during use to remove metal chips, dirt or shavings.
This will prevent scratching of your clamping mechanism.
C. If your material is getting scratched examine the Clamping Bar and Hinge for roughness or
burrs. Replace worn parts.
D. If you transport your Brake in the locked position, lock a piece of vinyl siding
or cardboard between the clamping members. Vibration during transport can
cause scoring of the clamping mechanism if dirt or foreign matter is present.
E. Replace vinyl strip if excessively worn or nicked.
UNEVEN BENDING
Uneven bending or “overbending” is material being bent more in one
section than in another.
Solution:
A. Make sure material is being locked down securely prior to bending.
B. Using Brake on uneven ground may cause some bowing or twisting to occur.
C. Check fasteners on Fixed Hinge and Wedges for looseness and tighten.
(see Replacing Wedges page 11)
D. Check for cracked or broken Castings. Look on the top and underside
of each casting. Replace part. (see page 12)
E. Uneven bending may be caused by operator pulling on one end of the
Lifting Handle rather than the center.
F. Transporting your Brake other than in the at working position may
cause it to bow.
G. Look for bow along the Fixed Hinge and Clamping Bar. These parts may
need to be replaced.
Trouble Shooting

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Clean Underneath Clampin Sur-
faces
Using solvent on a shop rag, clean upper
and lower clamping surface
as indicated and wipe dry. Do not apply oil
here
6
Replace Sliding Bar &
Oil Wedges
Replace Sliding Bar making sure that it
slides easily along the Clamping Bar. Wipe
up excess oil. Clean and oil the Wedges
now and regularly thereafter.
9
Cleaning the locking and clamping surface
Open Brake
Move Locking Handle to Right.
Follow steps 1, 2, and 3 in
reverse order to reassemble.
Remove Top Yoke Pin
With Brake unlocked remove
Cotter Pin from Top Yoke Pin
and disengage handle.
Remove Sliding Bar
Grasp and pull Sliding Bar to
the right and forward to remove.
Turn upside down and rest on brake
castings.
Loosen Dirt and Residue
Use Gum-Out®, WD-40®or quality com-
mercial cleaning solvent on a clean shop
rag and clean the bottom surface of the
Sliding Bar.
Clean Clamping Bar
Clean the bottom surface of the Clamp-
ing Bar in the same manner. Before
reinstalling check that screws securing
wedges are tight.
1 2 3
4 5
Tools needed: clean shop rag, commercial cleaning solvent such as Gum Out® or WD-40®, light weight oil
Wedge
Screws
“Spot” Cleaning
For everyday cleaning, a rag may be
used between the clamping surfaces
with the Brake assembled
7Oil Clamping Bar
Using any lightweight oil such as
“3 in 1”®or 30 Wt. motor oil, lightly lubri-
cate the Clamping Bar.
Note: Do not use graphite, silicone or
heavy grease as these “hold” dirt.
8

9
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Replacing the Vinyl Strip
Remove Vinyl Strip
Grasp other end of strip with pliers and
pull Strip out of slot. Check slot for burrs,
metal chips, dirt, etc. and clean if neces-
sary.
Drill Out “Center Punch”
Marks
Clean out slots that hold Vinyl Strip
at both ends of Brake using #26 drill
bit.
Tools needed: drill, #26 drill bit, hammer, slotted screw driver, light oil, pliers or vice grips, center punch, and safety glasses
2 3
4Replace Vinyl Strip
Replace Vinyl Strip by lightly lubricating
leading end with small amount of oil
while sliding into slot. Wipe o excess oil
afterwards.
5Punch Vinyl
When Vinyl Strip is in place “cen-
ter punch” both ends to prevent
slippage.
6
Close Brake
Move Locking Handle to left.
1
REPLACING THE STAINLESS BENDING EDGE
Loosen Stainless Edge
To loosen old Stainless Bending Edge, insert
screwdriver behind one end as indicated and
twist to release from end.
Remove Stainless Edge
Grasp one end of Stainless Bending Edge
with pliers or vise grips and pull away with
a twisting motion. Note: Stainless Bend-
ing Edge is not reusable after removal.
Install New Stainless Edge
Starting on end away from Locking Handle
align new Stainless Edge ush with end of
Clamping Bar and tap into place sideways
with Rubber Mallet.
After replacement, “Center Punch” Stain-
less Bending Edge on ends to prevent
possible sliding.
Open Brake
Move Locking Handle to the right.
Tools needed: slotted screwdriver, rubber mallet, vice grip or pliers, center punch, hammer, and safety glasses
1 2 3
4 5
Loosen Vinyl Strip
Push Vinyl Strip from one end by tapping on
the edge of upright screwdriver as indicated.
Make sure opposite end of slot is free of dirt
and obstruction. CAUTION: Avoid hitting
hinge with hammer.

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Replacing the Moving Hinge
Remove Hinge Pin
Grasp Hinge Pin at opposite end with pli-
ers or vise grips and pull Pin out. Moving
Hinge will now disengage and can be
replaced.
Replace Hinge Pin
To install new Hinge and Hinge Pin, have
assistant hold Moving Hinge while the Pin
is inserted. When reinstalling the Hinge
Pin lubricate the leading end with a light
oil. Be careful not to bend it.
Clean Out Hinge Pin
Before removing Hinge Pin, drill
out “center punch” marks from
ends of Hinge.
2 3
4 6
Tools needed: electric drill, small drill bit, hammer, small diameter hard wire or narrow punch, vise grips or pliers,
light oil, and safety glasses
REPLACING WEDGES
Remove Wedge
With the Sliding Bar removed and inverted
as indicated, remove the Flat Head Screws
holding the Wedge to the Sliding Bar.
Replace Wedges
Periodically check to insure that screws hold-
ing Wedges are tight. Loose screws will cause
uneven locking.
Clean Sliding and Clamping
Bar Before Replacing.
Clean surfaces. (see page 9)
Open Brake
Move Locking Handle to right.
Remove Top Yoke Pin
With Brake unlocked remove Cotter Pin
from Top Yoke Pin and disengage handle.
Remove Sliding Bar
Grasp and pull Sliding Bar to the right and
forward to remove.
Tools needed: clean shop rag, Phillips screwdriver, commercial cleaning solvent such as Gum Out®or WD-40®, light weight oil
Remove Handle
Detach Faspin and remove Lifting
Handle. Brake can be locked dur-
ing this operation.
1
Remove Hinge
NOTE: Have an assistant support the
Hinge prior to removing the Hinge Pin.
5
2 3
4 6
1
5
Loosen Hinge Pin
Using small diameter hard wire or narrow
punch and hammer, tap out Hinge Pin
from one end.

11
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Replacing the shoe Casting
Remove Hex Screws from Back
of Shoe Casting
Remove the four (4) Hex Head Screws
holding the Shoe Casting to the Bottom
rails front and back.
5 6
Open Brake
Move Locking Handle to right.
Remove Top Yoke Pin
With Brake unlocked remove
Cotter Pin from Top Yoke Pin and
disengage handle.
Remove Sliding Bar
Grasp and pull Sliding Bar to
the right and remove.
1 2 3
4
Tools needed: socket wrench with 7/16" socket, Phillips screwdriver
Remove Hex Head Screws
Holding Clamping Bar
This will allow you to reach at head
screws holding Fixed Hinge.
Remove Pivot Arm
Remove Pivot Arms and springs and
replace the Shoe Casting. When replac-
ing, make sure all fasteners are tight
and ush.
7
Remove Hex Screws from
Front of Shoe Casting
Remove Flat Head Screws from Fixed
Hinge on the Shoe Casting to be
replaced.

SIDING & ACCESSORIES
TRIM & MOULDINGS
ROOFING
STONE
WINDOWS
OUTDOOR LIVING
WestlakeRoyalBuildingProducts.com
© 2022 Westlake Royal Building Products
T30048341 2/22
Item # Description
®
10499 8'6" Hinge Pin
10500 10'6" Hinge Pin
10505 10'6" Tape Measure
10506 8'6" Tape Measure
10519 1/4-20 X 3/4" Hex Wash HD
10520 1/4-20 Nylock Hex Nut
10535 3/8-16 Nylock Hex Nut
10539 1/4" X 1 1/4" Faspin
11533 Back Rail Cap
10697 8'6" Bottom Rail
10699 10'6" Bottom Rail
10703 8'6" Moving Hinge
10705 10'6" Moving Hinge
10709 8'6" Fixed Hinge
10712 10'6" Fixed Hinge
10718 8'6" Clamping Bar
10721 10'6" Clamping Bar
10727 8'6" Slide Bar
10729 10'6" Slide Bar
10735 Fixed Yoke
10737 Pivot Yoke
10739 Pivot Arm
10740 Pro/Sp Material Stop
10741 Pivot Arm Tape
10742 Pivot Spring
10743 Locking Handle
10746 Lifting Handle Assembly
11625 3/8-16 X 3 1/4" Hex Cap Bolt
10749 8'6" Vinyl Strip
10750 10'6" Vinyl Strip
10752 Locking Block
10754 1/4-20 X 1 3/4" Phil Fl Hd Sc
10755 8'6" Stainless Edge
10756 10'6" Stainless Edge
10760 Yoke Pin
10761 3/32" Cotter Pin
10762 10-24 X 5/8" Phil Flat HD Sc
10763 1/4-20 X 3/4" Phil Fl Hd Sc
11329 1/4-20 X 1" Knurled Knob
10771 Slide Bar Retainer
10775 Locking Handle Grip
10798 10-24 X 5/8" Phil Pan Hd Sc
11418 Windy Handle Plug Kit
SP Handle Plug (2)
1/4" LockWasher (2)
1/4-20 X 1 3/4" Slot Fl Hd Sc (2)
1/4"–20 Hex Nut (2)
11424 Wedge (6)
12045 Windy“SP”Parts Bag
12062 C Casting
Item # Description Item # Description
*For Model Specic Parts, 8'6" part numbers are shown in diagram.
Parts List