New Project Maybe...

admin

This guy wants me to build a handrail for his porch. It will have A slight bend outward at the bottom step. Basically and arch )=( shape. <--- the equal sign is a step looking down.               I can do this no problem with 1" square tubing. I simply make a radius form using MDF and fasten it to a workbench and carefully bend the tube. However what about handrail molding and even flat steel like 1" or so. Anyone ever tried to cold bend that stuff with a DIY bender?
Reply:Ive just finished a very large handrail job with a bunch of arched balconie rails  I used 1" flat bar for the frame with cap rail on top of that and all bent by hand using a jig like wroughten harv uses. He posted a picture a while ago and I copied it . It works great if you do a search under his name you can find it.BTS Welding
Reply:I always bent the top rail using a torch. Draw the bend on a steel work table. Tack some scrap to the inside radius for stops. Tack one end of the top molding to the table in line with the pattern. Then heat red and bend the top molding an inch or two at a time being carefull not to strech it out of shape.
Reply:TPnTX, at our shop we weld the flat bar in the molded cap first and then bend it. Doing it that way keeps the molded cap from twisting when you push on it. We have a hyd. cyl. that we weld to the table and then just make many many little bends until it hits your layout.Most times its a 1" flat but we've had good success with 1- 1/2" x 1/4 flat also.We have holes in the table equal spaced from c/l of ram with vert pins and horiz. plates that go over the molded cap and keep it flat when its pushed.You can probably do the same thing with a 1 ton jack on its side.Take the project, life is a learning experience........Enjoy!         Good luck and keep us posted.