How to Bend Pipe Without a Pipe Bender





Introduction: How to Bend Pipe Without a Pipe Bender

Ahoy! So you have some pipe that needs to be bent but you don't have a pipe bender. Well no problem! This instructable will show you how to do it using sand and some creativity. 

The pipe shown here is 4130 steel - 3/4" in diameter with a wall thickness of 0.035".

The point of using sand is to support the pipe (keep it round) so that it does not buckle when bent. It worked for me!

Plan ahead - the end closest to the bend will likely have to be cut off and discarded.

Step 1: Pack Your Pipe

The first thing to do is to plug one end of the pipe.  I used a small carriage bolt that fit snugly in the end.  The next step is to fill the pipe with sand.  I used beach sand.  The sand should be nice and compact to stop the pipe from buckling. I used a rod to tamp the sand but what really packed it in was tapping (bouncing) the pipe on a concrete paving stone. 

Step 2: Bend!

Clamp one end to a form. Here I used a wine barrel planter and then added a rounded block (that just happened to be in my workshop) to get a tighter radius.  You will likely need a lot of leverage to bend the pipe. This piece was 4 feet long and it took some muscle to get the bend.

Step 3: Finish It Up

Cut the deformed end off. Clean out the sand. I used a piece of string with a rag on the end to get all the sand out.

The picture below shows the slight dimple in the center of the bend.  Unfortunately the method is not perfect but I am very happy with how this turned out (the pipe is a new steerer arm for my bamboo box bike )

One last thing - you can heat up the pipe with a torch before bending to soften the metal and get a cleaner bend.  I did not want to mess with the temper of the pipe so I did not do this.



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Can you use this technique on a 2 inch pipe.

Very nice tutorial, thanks!

My inner perfectionist wants to provide one correction, with your permission. The material you used (the 4130 steel) is most probably considered a tubing, rather than pipe. The difference is in their measurements and intended use. You measure a pipe by its internal diameter and you don't worry about wall thickness, whereas a tubing is measured by its outer diameter and wall thickness.
For all practical purposes, the bending method you described would apply to both.

Have a perfect day! :)

I've worked with pipe for 39 years, sir. And you definately have to worry about wall thickness. Your right about one thing, though. You measure pipe by inside diameter that is, up to 12", 14" pipe you measure by OD (outside diameter). Plus, not all tubing is measured by outside diameter, either.

Wall thickness, type of pipe material, copper, steel etc., diameter, and angle desired. All have at least some effect on bending characteristics. Sand or salt? Why salt, such a mess, so corrosive, etc. . Heat is tricky, too hot for copper is just right for steel and so on. Water with sand? That is pretty risky except for specialized circumstances and equipment. I agree, never use water especially if the ends are plugged airtight. Seems any pipe sealed airtight is risky with heat. Sand can be damp enough, or just air expansion itself, again depending on size, material, and wall thicknesses. I guess one of the big issues on a blog like this is the wide range of people with varying projects that might read the advice here.You guys are so helpful, with your professional, industrial experience. Thank you for your info.

Yes! Thank you. I love info like this.

Indeed, nice tutorial on a clever idea.
Thanks for your addition, too.

thanks,nice instructable.
I watched a doco on making slide trombones. to make teh bend they filled the pipe(brass) with briney/salty water. sealed each end with corks and then placed it in a larger freezer. once the briney water had gone almmost hard (it won't completely freeze or they didn't allow it to freeze) and that's when they bent it and it didn't crinkle.

They used this method in bending because that tubing is very thin and if you filled it with sand instead. You might end up with a wrinkle bend, that's definately not good for the instrument.

Sand bending has been used for decades for all sizes of tubes being bent. Not just small stuff. You need to wet it out to get it to compact, but one end (usually the long end away from the bend) needs to be left open regardless of if you;re using heat or not. When you heat it if sealed it will explode and hot sand burns aren't fun (ask a foundry worker). When you bend it sand will need to be displaced and go somewhere so one end needs to be left open.

If doing multiple bends you need to resettle the sand between bending or you will kink it. Voice of experience. If you look at the elaborate designs in F1 exhausts etc from the 70's and 80's (pre titanium days) hey were all done by hand from one piece of tube.

Wrong, much like the article. If you heat, you need to let the gas out. If you let the sand out, the pipe will kink. I weld one end shut, weld a large nut on the other, then bang, rattle the sand down before finally screwing a large screw as tight as i can into that nut. The pipe has to be packed very hard to prevent kinks.