Roll Bending and Arch

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So I planned to make this gate with an arched top. Pretty simple stuff.Looked all around at roll benders from $200-$8500. Found all the threads, links and videos. Thought any one of them would be nice to have but would rather hold out and budget for something nice.I've always had this page in my favorites http://www.metalgeek.com/archives/2005/05/01/000047.php and figured I'd give it a shot.Made a small jig I guess you'd call it out of 2 layers of 3/4" plywood. Sanded and squared the edges smooth. Bolted the jig to one of my small welding tables and tacked on a stop or holder. My small table is on wheels so I strapped it to my flatbed trailer behind the shop. Just to hold it steady. The whole jig and set-up took less than 45 minutes.I slightly undersize the jig to allow for spring-back.Grabbed the 1 1/4" 14 gauge square tubing, slid it in the stop and gave it a pull. This particular size and gauge was very simple to bend. I figure you could bend up to 2x2 11 gauge with the proper set-up.The in-fill of the gate is just temp'd up and tacked but the framework is about done.Last edited by 9er; 11-10-2009 at 12:20 AM.
Reply:Looks nice man!http://all-a-cart.comWelding Cart Kits and accessories
Reply:I can see you've put a lot of thought into putting that together. Pretty elaborate fill in the middle there. It's nice. Good job on the bend.
Reply:Thanks guys.Yeah, it takes alot to make it flow, I think. Here's one of the original renderings. I only had to change the bottom portion from the image, and do a little fine-tuning.We did about 60' of the short rail shown on the stem wall. Turned out nice.Last edited by 9er; 11-10-2009 at 12:43 AM.
Reply:I like that gate. Nice work..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Where did you get the scrolls at?  King Metal?  Or a different supplier?Very nice layout.  I really like this design.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:Great design.Good, simple solution to get repeatable, uniform bends without the $.
Reply:Very nice work, A+. Now time for a
Reply:This is one of the best posts I've seen in a long time. Great explanation of the techniques learned and applied. I did a copy and paste of the linked page and created a word .doc so as to have access to the information easily.
Reply:That gate looks great, good job... I like how the patterns/scrolls "flow" thru the middle horizontal bars. Bet the owner is happy!"hope for the best, prepare for the worst"Some of my equipment:Miller Millermatic 140Miller Syncrowave 200Lincoln PowerMIG 215
Reply:very nice gate and workmanship, do you make the scrollwork yourself?millermatic 200 millermatic 150miller bluestar 2Epurox / oxweld O/A
Reply:Kinda doubt he made the scrollwork himself if he built his first-ever plywood form for the arch.  Plus, it doesn't look like the steel was scrolled -- more likely cast in those shapes.It's probably King Metals' stuff.But that's great work -- a really beautiful design.Jack OlsenMy garage website
Reply:Nice gate.
Reply:Originally Posted by MarkBall2Where did you get the scrolls at?  King Metal?  Or a different supplier?Very nice layout.  I really like this design.
Reply:Originally Posted by 9erYeah, King is a great resource for these items. And if you're on their mailing list, they often send out 20% off deals for most steel items. You can aquire their artwork or files and drop them in a simple art program like the image above to get a good idea on a design and sell a job.
Reply:Thats real nice, I know what you mean by "flow". Thats what takes me the longest- design. And of corse everyone has a different taste.Peter
Reply:you are such a stud.
Reply:Figured I'd post up the rest--Blended and ready to sandblastApplying the patina, getting ready for clearcoatInstalled
Reply:Amazing work!Millermatic 252"Don't worry, he's got a welder, he can fix anything"
Reply:Very impressive!(Retired) Professional firefighter, amateur everything else I try to do...Oh yeah:  Go Big Red!   (You know: one of the 12 members of the Big 10 cuz we left the 10 members of the Big 12...)
Reply:I really like it too!!!!
Reply:Beautiful work!
Reply:That gate is freaking gorgeous!!!
Reply:Great work...I need to come up with a project that i can use some scroll on I like the color what kind of patina is that...is it just sprayed on?
Reply:Thanks guys. I really like how it turned out. The patina is a solution of ferric nitrate, ferric chloride, potash and distilled water that is basically sprayed on. However, I have an application and neutralization technique I use that gives me consistent results. Then three coats of clear laquer. It's not a cheap or easy process but lately we've had alot of interest and have gone thru nearly 10 gallons of solution in the past couple months.It's not too tricky but when you're doing 50+ feet, you want the first foot to look just like the last.great work