DIY Mandrel Bender
Intro: DIY Mandrel Bender
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STEP 1: Tube Holding Blocks
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STEP 2: 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:
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STEP 4: Making a Cut Out for Clamp
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STEP 5:
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STEP 6:
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STEP 7: Clamp Placement
Placed clamp to see how it fits now it's ready for welding
STEP 8: Prep for Welding
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STEP 9: Welded
I tig welded the clamp to the die using stainless steel filler rod
STEP 10:
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STEP 11: 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
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STEP 13: 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
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STEP 15: Clamp
I tested the clamp on a piece of .625" inch round tube
STEP 16: 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
After welding together I forged it with a hammer to harden it.
STEP 18: Grinding Mandrel to Size
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STEP 19: 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:
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STEP 21: Finished
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STEP 22:
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STEP 23:
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STEP 24: Checking Fit of Mandrel
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STEP 25: Tube Guide
I machined a tube guide from brass
STEP 26: Tube Guide
I drilled holes to mount onto a plate
STEP 27: Tube Guide Support
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STEP 28: All Together
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STEP 29: Crank Handle
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STEP 30: 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
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STEP 32:
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STEP 33:
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STEP 34: Worked Perfectly
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STEP 35: Time to Make Some Parts
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11 Comments
orange4boy 4 years ago
1.Where did you get the "gear weld on blank"?
2. What wall thickness is the tube you are bending?
Bonifabcustom 4 years ago
orange4boy 4 years ago
Cheers!
AbigailJ9 5 years ago
Very nice indeed. mandrel benders can be crazy expensive ! The only thing I might suggest is using a hollow tube to connect to the mandrel instead of solid. The reason I suggest this is lubrication of the mandrel.
It was asked earlier how the rod would not get stuck in the bending of the tube. To the other person; the tube that holds the mandrel is anchored at the other end of the rod so the mandrel actually does not go anywhere past where it started. It's purpose is a sort of anti-crush mechanism so it sorta needs to have a certain place to be during the process or you could use one of those sexy multi ball type mandrels which actually go into the bend a little.
Lubrication of the mandrel is extremely important and the hollow tube would allow you to feed lubrication up and into the center of the mandrel then out a couple of small holes in the mandrel itself as you bend.
Takdashark 7 years ago
First off, amazing work! Ia little confused how the threaded rod mandre functions. I feel like I'm missing something. The rod would and get stuck in the part of draw through with it, so there's definitely something I missed or it magic!
redchapman 7 years ago
This is really cool, thanks for sharing! Can I borrow that ball nose cutter? Haha.
I was searching around online and found these guys: https://www.highpurity.com/custom-fabrication/mand...
Would you recommend them as well?
rionela 8 years ago
very good i was thinkung to make the die mobile or somthing like this ones
ARJOON 8 years ago
impressive work but that tig weld :S
romulobc48 8 years ago
vincent7520 10 years 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.
NovelUserName 10 years ago
Very Impressive how well that works!