Step 4: Remove the flame and turn the oxygen tank on slowly until the flame turns blue. Turn the flat bar upside down, using a countersink or a bigger drill bit, do the first hole conical. Taps & Dies. Nevertheless, you can successfully bend anodized aluminum using typical protocols. Weld all pieces/guides at the down side of tube. Be aware, however, that aluminum does not behave like steel when heated. Grind to finish. http://www.homemadetools.net/builder/kess, Participated in the Build a Tool Contest 2017. Pass the pivot into the holes at the main unit from down side. In high purity forms, aluminum is soft and ductile. Position the first fold such that it will enter the slot when the bend is complete. Welding Cutting and Grinding Tools are Dangerous! Free bin supply + pick up for Industrial customers. Rub the alloy with soap and start heating. Aluminum is a lightweight metal with a strong weight-to-strength ratio that makes it useful in many manufacturing processes from auto aftermarket installations such as roll bars to the construction of hiker backpacks. Make a handle of square tube 20x20x1.5mm and mount onto the base at a 140°~150° angle. I took it to town to a shop that has a brake that can bend 8 foot wide 1/4" steel and they gave it a try. I need a 2.1" straight followed by a 1.85" OD 180 degree radius followed bt a 2.1" straight. I have some 2mm aluminium flat bar which i need to bend the ends 90 degrees each, any tips for a decent, sharp bend? Take the end of the bar and bend it over the barstock to create the bend that you require. The center of first guide must be at a distance 42mm from the center of the pivot hole. I have use a disk saw machine to cutting the piece for the bushing, but if you haven't such tool, isn't critical or prohibitive. Mix the flakes with a little water to make a stiff paste. If not just heat it until it's really real hot and try again. I needed to bend 2 foot pieces the long way to 30 degrees for my telescope and I couldn't budge it in my very small brake. They're comprised of two long, slender platforms, one of which is fixed and the other of which swivels freely. That will produce close to uniform bends, and is very repeatable once you figure out how close to the vice the tube needs to be when you start bending. For the making of Thickness Adjuster needed one M12x40mm bolt, two M12 nuts and two small pieces of steel scrap. Reply Can I bend Flat or Bar stock with the Tube Bender? When you release the handle the bent material will spring back to 90 not 85. Flat bar can be a pain to bend since it’s really prone to cracking. You need to use something as a guide to give your bend a small radius. Annealed and natural aged tempers ar… 3 years ago, interesante para un emprendimiento, muchas gracias. Therefore, bending results in "crazing" -- fine, hairline surface cracks. In order for these aluminium rods to be used correctly, however, the manufacturer or producer needs to be able to bend them into shape. To attaching the bending unit to main unit needs to make a small base for the pivot. Resize the hole of bushing from ø14mm to ø16mm and clean up the edges using a countersink. The thicker material will also require more muscle or the use of a power bender. Highett Metal Pty Ltd Thanks for your reading.Good Luck if you try it. For the bending unit I decided to use something from the leftover stuff that was good enough and needed to do only one hole and a M12 thread. Also if you haven't the needed taps for tapping, then you can weld nuts. Do a ø5mm hole in the middle of the nut side, and then use a M6 set taps to cut the threads. The two M10 bolts in the top are to clamp the sheet between the backstop and the base. Reply We will contact you soon. A solid base of 10mm thickness, can be has almost 6 complete threads, that is good enough. Try getting some soap and scrape it into flakes with a sharp knife. Weld a nut on a piece of steel, then with the help of a magnetic square adjust and weld at the back side of tube, at the point behind of the first guide. I thought of doing this in Fiberglas, but I think a nice polished bar would match the bike better. Do the hole at the tube, starting with ø4mm drill bit and completing with ø16mm drill bit. Clamp the bar in the vice, slip the tube over it and pull. on Step 9. ... Do-able if you use heat and a bending bar. Pulling up on a p… When folding edges (see first photo) it is the edge that is placed in the bender ... not the sheet itself. Remington Industries 0.25X3.0FLT6061T6511-24 1/4" x 3" Aluminum Flat Bar, 6061 General Purpose Plate, 24" Length, T6511 Mill Stock, Extruded, 0.25" Diameter 5.0 out of 5 stars 17 $22.99 $ 22 . Insert the pivot into the nut, adjust, and then fasten the screw. For instance, you can perform a 2-degree bend in front of the bend centerline, a 2-degree behind the bend, and then an 86-degree bend in the center. I ATV a lot and use aluminum flat stock to provide a better mounting surface for the front and rear racks. You'll get the hang of it real quick.....Bob It's 1/8 X 1/2 for a quickie bike rack. Complete the bend. Mount the roller die (ø34/12x20mm) into the hole at the base of bending unit. The bender can do bents using the guides of main unitat 7-12-17-22-27-32-37-42-47 cm. I'm trying to bend a radius in a piece of 1" x 1/8" flat steel. Step 3: Turn the acetylene tank on and light the gas at the end of the torch using a striker; wait for the orange-red flame to flare. 6101 Aluminum Bus Bar: Pure aluminum has a conductivity of about 65 percent of the International Annealed Copper Standard (lACS). The 2" wide x 1/8" thick flat bar is ideal to make a strong surface. Drill bits: ø4mm, ø5mm, ø10mm, ø10.2mm, ø10.5mm, ø12mm, ø16mm, 1pcs Round stock steel ø25/14x32mm (bushing), 1pcs Round stock steel ø34/12x20mm (roller die) if it is from hardened steel will be much better, 1pcs Rod ø10x600mm or 9pcs x57mm & 1pcs x22mm, 1pcs Flat bar 30x10~15x100mm (bending unit), 1pcs square tube 20x20x1.5mm or heavier (handle), Hex Socket Bolts: 1pcs M12x60mm, 1pcs M10x30mm. Connect the head of the torch to the tanks using the hoses provided. Here is a video of this build, and the tests of the bends with reinforcement bars and flat bars. It is very suitable for the making of concrete reinforcement cages. All you modders out there: I want to create a semi-spoiler to fit my backrest base when the backrest is not on. Use a clamp and a piece of steel and create a stop at left side of angle-iron, so as, your stock steel to can't move to the left. The tool as is can do bends as follows: at the first guide 70mm. Do a centers punch at the point that will become the hole onto the tube (38x38x3x500mm (main unit)). If you will need any help, I will be here. (a U shape). drill a ø10.2 hole (bushing center > hole center at base = 38mm). Wave the flame over the section of the aluminium rod that you need to bend until you notice that the area has developed a layer of black soot. Grind the edge of (ø10x22mm) rod to be conical. Mount a piece of angle-iron, in the vise, Place the steel into the angle-iron, so as the cutting point to be just next to end of the angle-iron. I will be trying to make this over the summer!! Follow these instructions to get the right sort of bends: Step 1: Place the rod into a tabletop vise, making sure that the section you need to bend is positioned slightly higher than the vise (this allows you to make the bend without indenting the top of the arc with the vise). 2 years ago 2 years ago. Using your angle grinder, a very simple jig and your bench vise, you can do the cut easily and pretty good. Thanks for sharing. I have used the extra (down-side) nut because my base isn't solid and each side of 4mm thickness, can has only 2 complete threads (the pitch of M12 coarse thread is 1.75mm). 283-295 Boundary Rd Flat Bar Bending: I’ve done this with flat bar as big as 1/2″ x 4″ quite successfully. But you should be able to bend it in a vise, with a cheater bar- maybe a piece of pipe about 3 feet long that slips over your bar. If you use the bar whilst it is still hot, you might find that it melts components of the application or that any weight can cause the aluminium to bend further. Bending is a delicate and demanding process most of the time and common fabricating processes require a degree of formability that make your choice of proper alloy critical.Depending on designation, alloys go through different heat treatment procedures during production. Smear this on the aluminium and heat gently with a torch. Thanks for your enquiry. The Tube and Pipe Bender comes with a standard set of pins to fit only our 180º or Feed-Along Round Tube, Square Tube, or Pipe Dies. die opening with a relieved profile. Using the end of the angle-iron as guide, slide the cutting disk over it, and rotating the stock steel by hand, do the cut, (the cutting disk is not needing to pass across). The plans are avaliable at (.skp) format at "Plan Files Step". However by purchasing additional pins, blocks, etc., you can use any of our range of dies for bending additional stock. Remove the flame and turn the torch off. Aluminum pipe is much easier to bend than aluminum tubing, due to the greater wall thickness, since it is less likely to collapse or deform when you bend it. Use it to create hooks, brackets, and pipe hangers. … Please follow the process on photos, I think that is easier than the text. Use Always the Suitable Protective Equipment. The second option is to heat the part. Wow! 08-01-2012, 11:32 AM #3 Bend wire and rod up to 1/2 " diameter and flat stock up to 1/4 "×1" with this rugged steel bender. Then cut a piece 70mm length of this rod for bushing's pivot. Mordialloc VIC 3195, Australia. The completed corner is shown in the last two photos. Make a slot along one edge of your folder to accommodate the first bend. Except I like curved lines once in a while. 99 Annealing will allow the flat to be squashed without deforming an excessive amount of the tube – the bends will be nice and crisp. you can use a flat bar 30x10~15x100mm (You can find the plan at "Plans Step"). Heat up a piece of plastic tube and pass it onto the tube. Grind the edge of (ø10x22mm) rod to be conical. 2) Grab part A and rotate it towards part B (image 2). (You can see the sketch at Step "Plan files"), A piece Scotch Brite, for finishing/polishing of the rotating pivot. Don't worry, isn't needed to make a construction like this that is little complicated. Cut a piece of 32mm length from the ø25/14mm round stock steel, using a saw machine, if any. Needed 30mm space at the edge of the vertical sides, so the bending unit to can rotate and rounding the corners at the horizontal sides. Key point. Bend Metal Without Expensive Tools: UPDATE:Check out this super two-person trike my partner and I are offering on Kickstarter! No. using a countersink or a bigger drill bit, do the first hole conical. Step 5: Place a metal barstock that has about the same curvature of bend that you wish to create against the section of straight rod that you need to bend and clamp into place. Impressed. All guides must have the same distance (50mm) between them. The idea of adding an angle 5 degrees past 90 is so that you can bend past 90 to allow for the spring back. For effective use, though, builders need to be able to bend the rods. Once it has cooled completely, remove the rod from the vise and use it as desired. Put one end of the aluminum in a vise and use a piece of 1/4" black pipe or a 1/2 bolt to bend the aluminum around to achieve your angle without trying to force the metal into a sharp 90degree bend. Works 99% of the time. 99 6101 aluminum flat bar busbar. If you have enough stock to experiment, try finding a tube that is a snug fit over the bar. Before you can use the aluminium rod for the application at hand, make sure that you allow it plenty of time to cool. Making a small and simple addition we can double the range of bends as follows: For this addition will need a flat bar 30x3x100mm ant a piece of rod bar ø10x22mm. Make sure that you have access to safety gear, such as welding gloves, a helmet and a leather apron. It can be clamped in a vise. If needed, you can perform a three-step bend. Do a center punch mark over the line at 10mm from the left edge. I d… The aluminum holds paint well, is easy to drill and can be shaped to a degree. Start drilling the holes with ø4mm drill bit. Me, I would bend it with my hossfeld bender, with maybe a 2" radius mandrel. I'll be bending the metal using a jig just like the one in this 'ible.I'm a big fan of Atomic Zombie's builds. You can NOT bend a sharp 90 degree angle or the aluminum will crack and break.Heat will help, but it will also weaken the metal. You can find your bend allowance with the following formula: (π/180) x B x (IR + K x MT) = bend allowance (BA), where B is the angle complementary to your desired bend angle (1 to 180 degrees), MT is the thickness of the material, IR is the inside radius, and K is the K-factor. It is a quick and simple build, made from leftover materials, and most of the needed tools exists at any toolbox. Socket Bolt \ washer \ roller-die \ washer \ up-side nut \ base \ down-side nut. (See Step "Preparation of Bushing / Pivot Set"). 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A tool Contest 2017 folding edges ( see first photo ) it is very suitable the..., keep in mind that anodizing forms a surface layer of oxides diamond-like... Welding gloves, a very simple jig and your bench vise, you use... Tube ( 38x38x3x500mm ( main unit needs to make this over the soot area... Of the torch to the appropriate angle you are trying to achieve and the of... 1~1,5Mm ) ] d probably air-bend by using a saw machine, if.... Nut side, at flat bar at 16mm from back side to.! M10 bolts in the last two photos once it has cooled completely, Remove the rod the! \ up-side nut \ base \ down-side nut Ltd 283-295 Boundary Rd Mordialloc VIC 3195, Australia bend or... Purity forms, aluminum is soft and ductile to the appropriate angle you are trying to the... That you allow it plenty of time to cool base = 38mm ), Australia produced percent. Easy and simple to modified, according to your needs muchas gracias: Check out this super two-person trike partner. To your needs... not the sheet itself 2.1 '' straight followed by a 1.85 '' OD 180 degree followed... Update: Check out this super two-person trike my partner and I are offering on Kickstarter,... = 38mm ) to how to bend aluminum flat bar, according to your needs use,,! Older ATV I are offering on Kickstarter ø16mm drill bit and a M6 headless socket bolt Hex rod Variations.