Tube Bending

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Hi All, It's been a loooooong time!I'd like to bend some lightweight tubing to make some gates.  I don't know the gauge, but it's about the lightest tubing you can get for chain link fencing.I have a 12-Ton bender with different dies.  I believe the tubing is 1 3/8" and there is no die in that size, so I tried a couple of different ones......one smaller and one larger.Problem is that the bend is not smooth.....in either one.  It either flattens or wrinkles.I'm wondering about the roller settings.  Currently they are set at the lowest level.  The way I read it, they should be set so that the tubing fits snugly between the rollers and the die.I almost bought one of those hand benders from Harbor Freight, but found this one at an auction, so got it instead.Anyway, I have never done any sort of bending like this, so any pointers will be sincerely appreciated.  I'm not an accomplished welder either, but I can "make it stick" (g).Regards,Jim Attached Images
Reply:Okay, best things to know: a short, short list and I will miss many points, several of which will wind up being important to you....Get the right size pipe. Or tube, as it were. If the die is a 1" pipe, then a 1-1/4" tube will be okay, but not quite perfect. A 1-1/4" pipe die is the same as 1-5/8" tube. A 1.5" pipe die will handle a 2" tube, and vise versa.Figure out the radius. Bend a section of whatever, and see how big the radius is along the CENTERLINE of the pipe. Not the outside, not the inside. To figger out easy-sleazy: Mark a piece of pipe and set that mark at the center of the bend in the die. Bend said pipe. Now, once you get a pretty good 90, lay it on cardboard or the floor, etc. and mark that center mark on the cardboard. Trace back to where the pipe quits bending on each side, and mark that point. Make that 4 times, and there is your circle. measure the middle diameter- not the inside edge, not the outside edge. EXAMPLE: Pipe bend mark and done 4 times on an X on the paper traced inside and out shows a circle which is 12.5" on the outside, and 11.5" on the inside, and it is a 3/4" pipe so the actual OD on the pipe is near 1" Well, roughly, you have a 12" circle, but that is more like a 6" radius. Think breaking a circle with 4 'L' marks; from centerline to the top center of pipe, and across to center of pipe...... THAT number is your radius. Figure out how much bend there is from a start line to the center of the bend, and then mark and bend the pipe. OR: Bend a pipe with some extra, and cut and weld to length. SOOO much easier if you are not building a critical part like a rollcage.Keep bends flat as it were; if you make 2 bends on a pipe, mark a line so the bends will not offset by a tiny bit- this makes a gate crooked right out of the box.Make sure the tube/ pipe you are bending is thick enough wall to take a bend without kinking. Too thin, you need a much better bender, which costs a lot more. On average, for a bender like that, sched. 40 pipe is a safe bet, sched. 20 might kink or ripple. For tube, .083 or .090 are as thin as you will get a good result with. .120 is good to go.To help line up pipes to get a good weld on a joint (You will bend, cut and weld rather than figure out how to repeat a pair of 90's on a plane and match diameter and bends....... trust me) Well, use a piece of angle- it can be clamped to the pipe, or the pipe can be laid into it. Automatically lines up the pipe for a straight, easy to tack true joint.To repeat a bend; mark the press for how high the bender pushes the material when you hit your angle. Many have angle finders. (Many have INACCURATE angle finders......) So, with a little trial and error, you can devise a way to hit the mark time and again, to at least get equal bends repeatedly.I'll let the rest of the guys chime in, with plenty of stuff I have forgotten.Oh yeah; 3M  8212 masks for welding galvanized.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:I hope I do not burst your bubble but I have that same bender and it will not bend tubing with any degree of smooth bend. I've tried bending water pipe, exhaust pipe, and  cyclone fencing pipe and none of them worked well.  However if you have some good results I would sure like to learn what you did.  Oh by the way I also have an Hershfield, And it isn't much for tubing either, although it will bend water pipe fairly well.Mac.
Reply:Have you tried packing the tubing with wet sand?Miller Syncrowave 350Millermatic 252/ 30A spoolgunMiller Bobcat 225g w/ 3545 spoolgunLincoln PowerArc4000Lincoln 175 Mig  Lincoln 135 Mig Everlast 250EX TigCentury ac/dc 230 amp stickVictor O/AHypertherm 1000 plasma
Reply:That is a pipe bender.  It doesn't bend anything well.  I sure doesn't bend anything thin wall or tubing. check google or youtube for modifications. Somebody made a nice press shear out of one of those.  There is a post on this forum.Tool Maker, What is a hershfield?
Reply:A Pipe Bender and Tube Bender are two different animals..   most true Tubing Benders have pipe dies available for them but not the other way around.. pipe is measured by the Inside diameter, tube is measured on the outside diameter..  This is why the pipe dies you have will not fit the tubing you have, you need to use pipe with the bender you have..tackleexperts.comwww.necessityjigs.comhttps://www.facebook.com/groups/mach...dingequipment/
Reply:Had to mod mine to get even a remote looking bend out of thin tube. You can see in the pics I bent a pipe, then cut it in half, and use it as a shim for bending tubing. I have nicer benders for nicer projects but like to use the POS because it is faster and easier to set up.http://weldingweb.com/vbb/showthread.php?t=61123
Reply:Originally Posted by DougAustinTXHave you tried packing the tubing with wet sand?
Reply:Hi All,I just tried bending some well pipe.  It bent fine.  Not all the way to a 90, but could have.Problem is......it takes too much muscle power and............therefore time.  There must be some way to bend tubing correctly.  I've hung many, many gates like that over the years and they were bent correctly.  So, it shouldn't have anything to do with the machine.  Maybe the dies.Still searching!Thanks,Jim
Reply:Originally Posted by desertjimHi All,I just tried bending some well pipe.  It bent fine.  Not all the way to a 90, but could have.Problem is......it takes too much muscle power and............therefore time.  There must be some way to bend tubing correctly.  I've hung many, many gates like that over the years and they were bent correctly.  So, it shouldn't have anything to do with the machine.  Maybe the dies.Still searching!Thanks,Jim
Reply:Jim,HF doesn't carry a Tube Bender, they do sell a Tube Roller but Rollers are used for rolling large radius curves, like a half circle or with enough practice you could even roll a full circle but they don't BEND tubing into corners and such.http://shopoutfitters.comCheck out SO for what a bender and a roller can do.You can also search the Internet and  forum for Homemade benders for tubing.Unfortunately tubing benders are not cheap, even when you build the frame of the bender yourself, the Dies for the Tubing is what cost $Ed Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:Originally Posted by Broccoli1Jim,HF doesn't carry a Tube Bender, they do sell a Tube Roller but Rollers are used for rolling large radius curves, like a half circle or with enough practice you could even roll a full circle but they don't BEND tubing into corners and such.http://shopoutfitters.comCheck out SO for what a bender and a roller can do.You can also search the Internet and  forum for Homemade benders for tubing.Unfortunately tubing benders are not cheap, even when you build the frame of the bender yourself, the Dies for the Tubing is what cost $
Reply:You guys think this'n would work for my purpose?http://www.harborfreight.com/tubing-roller-99736.htmlThanks,Jim
Reply:Originally Posted by Broccoli1Jim,HF doesn't carry a Tube Bender, they do sell a Tube Roller but Rollers are used for rolling large radius curves, like a half circle or with enough practice you could even roll a full circle but they don't BEND tubing into corners and such.
Reply:Originally Posted by desertjimThere must be some way to bend tubing correctly.
Reply:Got one of these too. Be prepared to cut key ways in the dies, and shaft if you really work it!  Attached ImagesDon’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:I have sold these and my customers say they are great for manual tube bending.Most were for marine railing.http://metal.baileighindustrial.com/...FYN_QgodFxAAnw
Reply:Originally Posted by DSWThe item you linked is what Ed was talking about. They do large radius curves, not small ones. I doubt that will do what you want.There are places that sell galvi elbows for stuff like this. Try King Metals.among others.http://www.kingmetals.com/Catalog/Ca...ogDetailId=967Here's a link someone posted recently for tube elbows.http://handrail-fittings.sharpeprodu...pe-tube-elbows
Reply:Hi yall,I made some pipes for a car with segmented bends,The customer went crazy when he looked at them, I made 2with different radiuses. showed him and he said,Man, can you do my whole system like that?Heres a pic of 2 1/4' pipes I did.It took me 15min. per pipe to do,(from cutting till finished as in the pics.Here is a pic. Attached Images
Reply:Check you local muffler shop.
Reply:Originally Posted by tapwelderCheck you local muffler shop.
Reply:Originally Posted by dubl_tDitto.Jim, take some scraps to an exhaust shop, they definitely have the machine to bend with, but not sure on the dies. Maybe 1.5" minimum?
Reply:Originally Posted by CEPSo far I've been happy with mine. http://www.jd2.com/c-12-tubepipe-benders.aspx
Reply:Originally Posted by a1998z3Not trying to mess up the thread, but could you explain your design;the pump, and isn't that a manual made into air? I've been looking to make something simular. Thanks. desertjim i hope you don't mind.
Reply:I have used the HF type bender for years and have it hooked to an air powered pump.  It is great as long as you bend PIPE only.  no tube, conduit etc.  You can also bend channel and flat with it.  I made a flattner attachment to flatten pipe ends for easier weld when they don't need to be coped. It works on sch 40 or 80, but nothing else.  We have made hundreds of industrial picnic table frames with it.  I have also made about a dozen commercial playground and swing sets.  The smaller (up to 2" pipe) is better.  I am noticing pipe quality going down in the last couple years and have had a small percentage of kinks.  The Korea pipe seemed worse than the Thailand pipe on my last load.I think I spelled it wrong'  I will have to look it up. But it is one of the best known benders for Iron. Mac
Reply:CEP, thanks.
Reply:[PDF] atsm, HOSSFELD UNIVERSAL® BENDER - Metal Benders ...http://www.hossfeldbender.com/.../Ho..._Tooling_Broch...  Mac
Reply:For pre-bent elbows for fence material, try Schorr Metals in Placentia Ca. http://www.schorrmetals.com/If you want a bunch of elbows bent up, let me know what sizes, what thickness, and what radius. I could bend up a gaggle of them and ship them to you pretty easy. I could put a 90 on a 4' section, and then you could cut to length and weld on type of gig. I use a JDsquared model 3. You should look for a used one on www.Dezertrangers.com in the classifieds. They are there all the time.Last edited by Rojodiablo; 11-09-2012 at 12:09 AM.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:I made a got trikes bender, modified a harbor freight air hydro ram. It works beautifully. 1.75 x .120 tube all day easyHTP Invertig 201Lincoln Idealarc SP250Miller 180 AC StickBy farmall:They should have held the seagull closer to the work, squeezing evenly for best deposition.