No matter what your hobby, sometimes you need to bend some light weight metal into nice, circular shapes. This instructable will show you how to make a metal roller out of old printer rollers and some angle iron.
So far, I have used this bender to make circles out of 1x1/16 aluminum for some of my hobby robots, to bend some 1x1/8 inch aluminum into a perfect circle for a US First Robotics high school team I mentor (Go Team 1631), and to bend two 5 inch wide 1/8 inch steel sheets 9 feet long for a fire pit I am making (but that’s another instructable).
This instructable will have you cutting metal and braising. Don’t forget all the safety rules involved with each of these activities. If you are new to any of the tasks below, I recommend looking up safety tips on the internet before trying something new. As you will see in step 10 “Next Time” I made a few errors on this one, but I finished with all my fingers and toes intact. That’s a good thing.
This is my first of hopefully many instructables, so if something doesn’t make sense, just ask, and I’ll try to explain it better.
Step 1: Parts and Tools
3 Printer rollers removed from old printers
2 4 ft pieces of 1x1 Angle Iron
1 3 ft piece of ¼ in C-Channel
1 3 ft piece of 2 x ¼ inch flat metal
1 Conduit pipe holder
1 ¾ x 9 inch bolt and nut
Scrap rebar or other metal
Magnetic 90 deg holder
3lb Sledge Hammer