Production build.....radius pieces...

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Hey guys,I posted pics of the alum. wheel chocks I started fabbing & the first (2) were sold. I now have orders for (8) more sets & I need to make some spare ones to have on hand. Since I've been doing production design for a number of years with our company, I now need to do some for myself. I can cut & bend the pieces quickly & need to bend the radius consistenty so as to maintain productivity & profitability. Putting the radius takes the most time manually to insure fit & alignment.It only took a few minutes to visualize what I needed to do. Got into the residual box & started pulling material to layout after making a rough drawing. I was pretty sure I could make it simple yet effective. The pics are kinda self-explanantory, although I'll explain the start-to-finish concept.1) Use the standard Gr10, 3/4" X 14" bolt for the pushrod.2) Pushrod plate(12"L X 2"W X 3/8"T CR) drilled for (3) width positions for the radius straps, reinforced & welded to the pushrod.3) Radius straps cut & assembled using CR 1"W X 1/8"T X 13"L(long set), & 1"W X 1/8"T  X 10"L(shorter set). The radius depth is 1.125" for the long set & 1" for the short set. I used 1/2" solid sq. to frame. I drilled & tapped the center joint for 1/4 X 20 thd for mount stud.4) The roller frame is made with 1.5" X 3/4" rect. tube, 14"L X 12"W. I made (2) sets of rollers, 1 1/4" dia & 1 1/2" dia, used .625 dia. pieces of residual cutoff threaded rod for axels & notched the frame for location. I will notch additionally as I need to shorten the roller distance if necessary.5) Tested with 7"W X 12.5"L X 1/8" alum as that is the chock W & L. Worked quite nicely & will definitely save time($$$). I also did a test on narrow stock using only one of the radius legs....also worked nicely. Gonna try some sheet steel up to 1/8" tomorrow & see how it goes.Anyway, just wanted to help those who do production runs making multiple pieces with the same configuration. Jigging & fixturing makes for easy fabbing multiple pieces with repetitive consistency. This unit I made to handle up to 14" length & 10"W for the smaller pieces I need to do on occasion. Ask if anything needs clarified.Gonna need (4) posts to get on the (16) pics, so PLEASE give me a few minutes to get them all on. Thanks....Denny Attached ImagesComplete Welding/Machine/Fab. ShopMobile UnitFinally retired*Moderator*"A man's word is his honor...without honor there is nothing.""Words are like bullets.... Once they leave your muzzle, you cannot get them back."
Reply:Group 2.....two more to go... Attached ImagesComplete Welding/Machine/Fab. ShopMobile UnitFinally retired*Moderator*"A man's word is his honor...without honor there is nothing.""Words are like bullets.... Once they leave your muzzle, you cannot get them back."
Reply:Group 3: One more to go.... Attached ImagesComplete Welding/Machine/Fab. ShopMobile UnitFinally retired*Moderator*"A man's word is his honor...without honor there is nothing.""Words are like bullets.... Once they leave your muzzle, you cannot get them back."
Reply:Last group: Ask any questions if needed. Thanks...Denny Attached ImagesComplete Welding/Machine/Fab. ShopMobile UnitFinally retired*Moderator*"A man's word is his honor...without honor there is nothing.""Words are like bullets.... Once they leave your muzzle, you cannot get them back."
Reply:Post 3, pic 1 & post 4, pic 2 the roller framework.  Did you have to modify the placement of the rollers for the difference in the material width?  Or as demonstrated in Post 3, pic 4, the rollers were set too far apart to begin with?Just curious & pretty handy jig.  I might borrow that idea.MarkI haven't always been a nurse........Craftsman 12"x36" LatheEnco G-30B MillHobart Handler 175Lincoln WeldandPower 225 AC/DC G-7 CV/CCAdd a Foot Pedal to a Harbor Freight Chicago Electric 165A DC TIG PapaLion's Gate Build
Reply:Hey Mark,The first sample with the wide piece didn't have enough radius to match the chock, so I added the 2nd set of notches to move in the rollers & re-bent. This made it right on for the chock radius. I'm gonna add a few more notches & make a couple more roller sizes to test variances. All in all, it is really gonna save time to maintain a decent profit margin so I can keep the price where they will be much less expensive than ordering them. Thanks for the query.DennyComplete Welding/Machine/Fab. ShopMobile UnitFinally retired*Moderator*"A man's word is his honor...without honor there is nothing.""Words are like bullets.... Once they leave your muzzle, you cannot get them back."
Reply:Nice work.  Two questions.. on the photo of the completed chocks, there appear to be some screws or pop rivets displayed in the center.  What is that for?  (a reflector?, name plate?)  Also, would the chocks be enhanced with a large slot to act as a hand grip point somewhere on the back side?Again, nice job on build for the press bender.--zip.
Reply:there's a handle fixed the the rear of them
Reply:the slot would be a good addition opposed to the handle, would be cheaper