twisted steel rope

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I'm looking at making a twisted steel rope bar rail. I would like to have a diameter of 2". I'm wondering if anyone has any suggestions as to how to twist the steel bars. I think I can use 3 - 1" round bars assembled to look like rope. The problem is I think I'm going to require quite a bit of force to bend all three together. The rail will be about 13' long. All suggestion are welcome. TIAModyCalgary, AB
Reply:Are you following a certain theme?Could you use wire rope (cable)?Good Luck
Reply:Humugus task, humungus $$$$.  I just don't believe it's practically doable.
Reply:Stack the three on top of each other and clamp in a vise or side by side on a table top heat it up with a torch and twist it with an adjustable wrench.....Mike
Reply:sometimes You Can Get The Big Stuff From (used Of Course) From The Elevator Companies
Reply:Originally Posted by 84zmikeStack the three on top of each other and clamp in a vise or side by side on a table top heat it up with a torch and twist it with an adjustable wrench.....Mike
Reply:Before you try to "twist" the three piece together, first tack or moderately weld the three pieces together on one end, otherwise they will all slip around on you.  I do some of this with 1/2 inch rod (not quite the same as 1") but I have just used a pipe wrench with a small 'cheater' bar on it... not too bad, but you need to weld it together as you proceed furher with the twisting.AL Bachman
Reply:i should have read closer   he wants to use  solid stock  sorrybut yes  i got   115+ feet of used  elevator cable  (3/4 inch if i remember right)about "twenty five years" ago for next to nothing from a company in tulsait was just sitting out back on a spool
Reply:The twisting part is doable, it would take some time though. I think the problem would be keeping the rail straight. I'll bet it would look like a 13' curly fry without something BIG holding it straight.Braiding might be easier. It would take a LOT of time though.Miller EconotigCutmaster 38Yes ma'am, that IS a screwdriver in my pocket!
Reply:2" final diameter is pretty big- most pipe rails are only 1 1/2", and I find that is about right for the hand.But the answer to how to do this- do what they did in the old days- cheat.Old time high end blacksmiths would not actually twist three pieces together. Instead, they would forge 4 grooves down a single piece of round bar, then twist that. When you are done, it looks like rope, but its still just one piece of material. Much easier, stronger, no internal rust possible.You heat the piece up in a forge, a foot or so at a time, and forge the grooves in, then, when its all done, you twist it. Guys who do this all the time either build or buy twisting machines, which do this cold, and keep the material straight. Here is a link to the type of tool you use to forge the grooves-http://www.blacksmithsdepot.com/Temp...e_Spring_SwageOr you could make your own- for one piece, you could use mild steel. Grant uses heat treated 4140, and his swages last for years, but he is a pro.The thing is, with a well equipped blacksmith shop, with a forge, a power hammer, tooling and a twisting machine, this is not a tough job- I could do this in a day, easily- but it takes a few years of practice, and a lot of expensive machinery, to make it look easy. Theoretically, you could cut the grooves one at a time with a chisel, hot, then hot twist the whole thing with a big pipe wrench and a rosebud. Might not turn out as nice, especially the first time, but you could do it.
Reply:There's nothing real in a bar; It's all illusion and delusion!Excuse me - Except for the cash register!So, maybe a tube could be tightly wrapped with rope!Make it so the drunks can argue about how it's built!How dark is the bar? Good liquor, served fast?
Reply:Three 1" bars is to big. Try 3 5/8" or 3 3/4" still going to suck though. You could try using a lenghth on angle iron as a track to keep it strait and you will need a rose bud tip for your torch and about 100 bottles of gas. Post pics if you do it. Steel Thunder Welding LLC. St. Thomas VI USAMM350PBOBCAT 3MAXSTAR 150 STH375 EXTREME PLASMA6.5 HP COMPRESORDEWALT 18, 24, AND 36 VOLTO/A TORCH SETAND SO MUCH MORE I DONT REMEMBERALL IN MY 2005 2500HD EXTENDED CAB L/B
Reply:I'm at home now and have no catalog's but I'm pretty sure you can get 6x7 45mm wire ropeA good guess is better than a bad measurement
Reply:Many years ago a guy I worked with did the twisting bit with 1/2". He welded the ends together and grabbed one end in a 4 jaw and I forget what he had on the other end of the lathe, it was something he had made up. It worked well. I think it was linked into or onto the tailstock and he wound it out as it turned. His was a much shorter length but I guess you could have a join.Clive
Reply:I live in the woods in an area harvested for timber several times.I constantly run across cable used to haul logs uphill-it makes a mess in my rototiller and my DR mower.The cable sometimes is about 1 1/4" and pretty rusty but stiff.I guess you could heat and fill it with solder to get a reasonable looking rail.If you just want the cosmetic look of rope why not twist nylon rope around a rod-then cover with epoxy for abrasion resistance?  Steel will rust quickly, and repainting into the greeves will be a heck of a job.
Reply:Wire rope will act totally differently than an actual twist, whether its one piece, or three. You can probably buy what you want from these guys-Tornado Supply2414 West Skelly DriveTulsa Ok 74107918) 445-3063I dont think they have a website, but they make, and sell oddball twists.So they have built the equipment, probably a 20hp or so 20 foot long twisting machine, have already worked out all the bugs, and will just sell you the finished product.
Reply:was looking at some 1/2' today in a triple s steel catalog.they have all kinds of sizes, i think i seen 1 1/2" . i've got them to get me stuff before from there suppliers that they did not have in there catalog. its worth a shot.triple s steel    713-697-7105houston tx Lee
Reply:WWW.TSDISTRIBUTORS.COM. This is triple s website. I use them all the time great service and they have 2"   "SF 801222 2" sq 47 1/4" long 53# $36.00 ea. or $30.60 for $10" page 107 in the 2007 catalog. I made an order to day with them for gate openers. Steel Thunder Welding LLC. St. Thomas VI USAMM350PBOBCAT 3MAXSTAR 150 STH375 EXTREME PLASMA6.5 HP COMPRESORDEWALT 18, 24, AND 36 VOLTO/A TORCH SETAND SO MUCH MORE I DONT REMEMBERALL IN MY 2005 2500HD EXTENDED CAB L/B
Reply:If it has to be metallic for the feel, but nothing else really matters, maybe try soft aluminum tube- the stuff for A/C systems. We used to screw around at my old shop and do stuff like that, but never for a project. Usually we were just making lousy tube into scrap to sell later.And then, after so much work...... you have it in your hand, and you look over to your side...... and the runner has run off. Leaving you holding the prize, wondering when the runner will return.
Reply:When I make twist damascus steel, I weld up the pieces on the ends.  Then clamp one end to a vice and the other end to a big rachet wrench.  I have a piece of pipe about a foot long, around the piece on a stand.  Then I take a big rose bud and heat a small area and wrench it, move the pipe over that area and heat the next, etc. Works like a charm to get a nice, straight piece with an even twist.  I've never tried it with something like 1" rod though.  Usually I'm using a 1"-1 1/2" pipe to contain all of it.