Introduction: Creating Small Radii in Metal Wires + Werkplaatsidc

In this instructable you'll learn how to bend tubes with your own homemade device. First I'll show you how to make your own and then explain how to bend the wires.

If you want to know how to bend small radii in metal tubes, head over here.

Here's what you'll need:

- A wooden plank, may be MDF, similar to de size shown in the pictures

- 4 screws

- A metal tube, 2 cm diameter or larger, aproximately 50 cm long

- A metal tube, with the diameter of the desired radius of the bend, at least 20 cm long

- A clamping screw

- A belt or tilting saw for wood

- A saw suited for metal tubing

- A drill suited for metal

- A metal drill bit the size of the thinest tubes

- A metal drill bit the size of the wire that you want to bend

- The metal wiring that needs to be bent

Step 1: Creating the Wooden Base

This part is made of 2 layers of wood. The lower one supports the wire and the tube that creates the bend. Make sure the tube is in the middle of the circle on the right. This tube is the smallest of the 2 diameter tubes and is about 10 cm long.

The top one is ment to align the wire to. Screw it down so there's just enough place between the side of the plank and the tube for the diameter of the wire.

Step 2: Making the Handle

The handle consists of two tubes. Drill 2 holes the size of the small tubes. One almost on the end of the hanle and one about 5 cm further (depending on the radius chosen for the wooden part under it).

Cut the smallest tube off at about 15 cm. Drill a hole in it almost at the end, the size of the wire that will be bent. The wire part will make sure the tube doesn't fall out.

Assemble as seen above.

Step 3: Assembly

Clamp down the device on a table and slide the handle over it.

Insert the wire between the wooden support and the bending tube.

Step 4: Bending the Tube

Simply turn the handle to bend the wire around the bending tube. There's some flex in the metal wires so make sure to bend a little further than desired.

If you're not sure whether it's bent far enough yet, take it out and measure it. If you want to know exactly how to measure out the place where the bend has to come. Head over to my first instructable on bending metal tubes.