Instructables
Picture of DIY Mandrel Bender

.

 
Remove these adsRemove these ads by Signing Up

Step 1: Tube Holding Blocks

Picture of Tube Holding Blocks

.

Step 2: Die

Picture of Die

I got a gear weld on blank and cut the profile of the 5/8 tube in it , using a 5/8 ball end cutter.

Step 3:

Picture of

.

Step 4: Making A Cut Out For Clamp

Picture of Making A Cut Out For Clamp

.

Step 5:

Picture of

.

Step 6:

Picture of

.

Step 7: Clamp Placement

Picture of Clamp Placement

Placed clamp to see how it fits now it's ready for welding

Step 8: Prep For Welding

Picture of Prep For Welding

.

Step 9: Welded

Picture of Welded

I tig welded the clamp to the die using stainless steel filler rod

Step 10:

Picture of

.

Step 11: Back In Mill

Picture of Back In Mill

I put the welded parts back into the milling machine indicated it straight ready for the cut with the ball nose cutter

Step 12: Blended In Ball Nose Cut

Picture of Blended In Ball Nose Cut

.

Step 13: Machine Clamp

Picture of Machine Clamp

I screwed in the opposite side of the clamp to the die in the vice so I can hold it ,so I can machine it with the ball nose cutter

Step 14: Finished Machining Clamps And Die

Picture of Finished Machining Clamps And Die

.

Step 15: Clamp

Picture of Clamp

I tested the clamp on a piece of .625" inch round tube

Step 16: Mandrel

Picture of Mandrel

To make the mandrel I'm using a piece of M8 metric threaded rod , I put two stainless screws on the end of it getting them ready to weld together

Step 17: Mandrel

Picture of Mandrel

After welding together I forged it with a hammer to harden it.

Step 18: Grinding Mandrel To Size

Picture of Grinding Mandrel To Size

.

Step 19: Grinding Mandrel

Picture of Grinding Mandrel

To bring it to the right size and shape I put the end of the threaded rod into a drill then I sanded it on a disc sander,

Step 20:

Picture of

.

Step 21: Finished

Picture of Finished

.

Step 22:

Picture of

.

Step 23:

Picture of

.

Step 24: Checking Fit Of Mandrel

Picture of Checking Fit Of Mandrel

.

Step 25: Tube Guide

Picture of Tube Guide

I machined a tube guide from brass

Step 26: Tube Guide

Picture of Tube Guide

I drilled holes to mount onto a plate

Step 27: Tube Guide Support

Picture of Tube Guide Support

.

Step 28: All Together

Picture of All Together

.

Step 29: Crank Handle

Picture of Crank Handle

.

Step 30: Bottom Of Crank Handle

Picture of Bottom Of Crank Handle

I made a cut out for the tube clamp and a bored hole that locates the die

Step 31: Ready To Test

Picture of Ready To Test

.

Step 32:

Picture of

.

Step 33:

Picture of

.

Step 34: Worked Perfectly

Picture of Worked Perfectly

.

Step 35: Time To Make Some Parts

Picture of Time To Make Some Parts

.

vincent75208 months ago

Only on Instructables can you find people crazy enough to make a bender that I'm sure works even better than the manufactured ones !!!…

Thank you.

This is perfect.

Again thanks for posting.

NovelUserName10 months ago

Very Impressive how well that works!