Introduction: Tube Bender

I would have liked it to make a new seat for my recumbent bicycle and for it was necessary some aluminium tubes and to bend those on proper shape. In our town I have not found a place to bend some tubes and I have decided to make my own tube bender for this work.

Step 1: Preparing

First time I went to scrap metal depot to find the necessary materials. I found some rusty pieces there. At home prepared the other pieces. I rounded the sharp heels of the laminated wood base, and my friends and his dad helped me to weld a handle and one more piece on the main forming wheel.

Step 2: Mounting

Once all the components was together, I installed bearings in the wheels, I put all components an the base ti find the correct position and place for the components and I drilled the holes for each pieces. I used M10 metric bolts to obtain a massive construction, and because the support for the wheels from the scrap depot was also very thick and robust.

Step 3: The Result

Immediatly after the assemling I tested my tube bender with a piece of plastic pipe with aluminium insert. I also drilled two more holes for fixing the base on a bigger working table. The whole tube bender is portable, the maximum dimension is ca. 40 cm on each side, and it's really heavy. I will use this only for 20 mm diameter aluminium tubes for my new seat.

Step 4: First Use

Comments

author
spark master (author)2016-02-16

err what di the wheels come from....I mean , I can bend emt I did it long enough, but what kind of wheels and then the frames to hold the wheels. Perhaps a smattering of theory of why you do things the way you do. Plus allowances, for bends.

thanks

author
lecgo (author)spark master2016-02-18

The wheels are from scrapyard, EMT also working, holding frame is plywood and also from scrapyard are the wheel holding metal pieces, Bend Allowance BA=90*(3.14/180)*(60+(16/2/20)*20)=106.76mm
90degrees of max bend, pii, 180, 60mmradiusofthewheel, 16/2mminnerradiusofaluminumtube, 20mmouterdiameteroftube.
Formula must be corected if tube has 22 or 16mm outer diameter what actually are the possible tube sizes.

author
alan.swaffer (author)2016-02-18

If the handle was cranked to clear the other pulley it would be possible to bend up to 180 degrees.

author
jhon wuba_nyserq (author)2016-02-17

Nice.

author
lbrewer42 (author)2016-02-17

Great build - thanks for sharing this.

author
bricabracwizard (author)2016-02-07

Can you show us with a video how you work your tube bender?

author
lecgo (author)bricabracwizard2016-02-16

Yes, now I have the video: https://www.youtube.com/watch?v=rFhxoYIEGno

author
bricabracwizard (author)lecgo2016-02-16

Thanks!

author
stephenfitton (author)2016-02-16

Congratulations, to you as. You....

Have covered the one point missing from most tube benders,

By using two wheels same size flat spots are overcome in your bending,each wheels slight rotation while bending compensates for what otherwise is drag causinng tube to collapse into flat spots

Again congradulations

author
pdub77 (author)2016-02-16

This is great! Thanks so much for this idea. I am making one of these before too long.

author
3DWulf (author)2016-02-16

Love it! Very creative use of old materials and limited space.

if you could have put your template under the wheels so you could align your work on the fly that would be a big help. This should be possible if you use a template that is the same thickness of you tube.

author
lecgo (author)3DWulf2016-02-16

Thanks for your ideea, it's really good! I will try it on the next project.

author
SexyWood (author)2016-02-16

how do you bend back to back bends of opposing directions?

author
lecgo (author)SexyWood2016-02-16

That's a good question, because many time the bending are too less or too much. If it's too much and need to bend back I use the same wheels, I fixed the tube between them and I pulled with my hands the tube. It's not the best way, but it's work. For a quality work must find a better solution in the future.

author
flyingpuppy (author)2016-02-16

This should be in the essential tools list of any workshop. Thanks for the tutorial.

author
myplace2 (author)2016-02-07

excellent,just what I have been looking for. I will be making similar soon I think.

author
doobie69doo (author)2016-02-07

The easy way to make this bender is to buy pulleys for a clothesline.

Drill several holes to attach with screws to the wood base, I attached it to my wood worktable so I could remove it and adjust the wheel distance for different size piping

remember not to use plastic clothesline pulleys

works great

Good Luck

I

author
purpelcraze (author)2016-02-07

even if it duz creas the toob if you fill it with sand befor you bend it it will prevent it frum crumpeling as mutch tape off the one end fill with sand then tape off the othere i dont have a pipe bender eather i used my reas hitch on my van to bend pipe but the sand keeps it frum kinking or colapsing & duz a good job

author
lecgo (author)purpelcraze2016-02-07

Yes, that's the method! thanks for remind me

author
Fredrockinva (author)2016-02-07

Nice work. No problems with creasing the tubes?
I bet you could cut a handle into the base, make that much more portable.

author
lecgo (author)Fredrockinva2016-02-07

Since I finished the bender, I didn't had time to try it with aluminium tubes, just with an plastic pipe, which is really soft. I hope next week I will try to bend some alu tubes, and I will see how it work

author
ScrappyGirl (author)2016-02-07

Really sweet, I will modify my tube bender now! Thanks!

author
wold630 (author)2016-02-05

Great project!!

author
lecgo (author)wold6302016-02-06

Thanks

author
kylegilbert (author)2016-02-05

Great idea. Where did you get the wheels?

author
lecgo (author)kylegilbert2016-02-05

Hi. I have found them on a scrap metal depot, I think they was parts os an old mining device.

author
keets (author)lecgo2016-02-05

Great bender! Good thinking.

The 'wheels' looks like some wheels of an sliding door. Old barns do have those.

The door is hanging on this hooks. On the inside of the barn is just an iron bar where the wheels 'ride' over.

author
ThatMike1 (author)keets2016-02-05

idler pulleys from a lawn mower deck would work

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