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Tube bender build

 
 
Post new topic   Reply to topic    Difflock Forum Index -> 4x4s -> Custom Builds
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aniesigh
Articulating


Joined: 15 Jul 2009
Odometer: 795
Location: north devon


1991 Suzuki Samurai

PostPosted: Tue Jun 12, 2012 10:05 pm    Post subject: Tube bender build Reply with quote

Not too sure if this belongs here...feel free to move it if you like mods,

Thought i'd share the build of my new tube bender,(may be of interest to some) didn't fancy doing the new truck build with a centrepress bender, if not purely because its hard work! plus hopefully can make some ££ on the side doing bits and bobs, will be buying Bend-tech soon so can design stuff on laptop and acurately bring them to life, seems to get some really good reviews!

so anyway, i cheated and ended up buying the bender arms, had the drawings to get them machined myself but by the time i had bought/made pins and bought a degree ring the price probably wouldn't have been much different! Matt at stakesys did a good price Wink





looked around on the net//youtube etc, theres loads of people converting them to hydro in different styles, i prefer the horizontal ones as although it takes up more space its easier to handle a 7.5m length of tube horizontally and easier to visualise whats going on!
Hydraulic wise...most use 230v motors rigged to pumps which is great but they don't half make a racket, its not that big'a deal but i liked the idea of not having to keep turning it off between finishing a bend and setting up for the next. also with the setups that use a spool block you have to stand where the lever is while bending, i fancied being able to move around so i can get a better view of whats going on.

Soooo.....i bought the hydraulic setup from a lorry tail lift, ram was about the right size and DC pump means i can have it operated from a wander lead. it will also be 100% portable.





mocked it up roughly, then made a framework for it to all sit on












__________________________________
1990 Suzuki Samurai 1.9TDI (sold)
http://forum.difflock.com/viewtopic.php?t=53747

new truck build thread:
http://forum.difflock.com/viewtopic.php?p=595221#595221
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aniesigh
Articulating


Joined: 15 Jul 2009
Odometer: 795
Location: north devon


1991 Suzuki Samurai

PostPosted: Tue Jun 12, 2012 10:06 pm    Post subject: Reply with quote



Ram didn’t have an eye at each end but managed to butcher the part from the tail lift that the ram slotted into a useable fitting to go onto bender arms





Then a couple months passed by, as when I tried to get it running initially although it powered out fine, I couldn’t get it to retract as the original hydraulic line/valves had flow restrictors in them to make the tail lift drop controllably, but in my application meant I couldn’t close it for s***!
That kind of ruined my motivation for it, coupled with a lack of funds and time it sat unfinished until this weekend when I got motivated! Went to local hydraulic supplier and bought a diverter valve, in one position the ram extends , in the other position it returns the fluid from the ram back to the tank through a newly fitted return line.

On with the frame:










Pretty much finished now, just need to get a 12v solenoid (motor and solenoid was 24v, motor runs fine just slower on 12, solenoid won’t operate!  ) and need to sort return springs, was waiting to check it does return ok with the new hydraulic setup, which it does! Very Happy and of course got to purchase a die set, need to save up!



__________________________________
1990 Suzuki Samurai 1.9TDI (sold)
http://forum.difflock.com/viewtopic.php?t=53747

new truck build thread:
http://forum.difflock.com/viewtopic.php?p=595221#595221
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aniesigh
Articulating


Joined: 15 Jul 2009
Odometer: 795
Location: north devon


1991 Suzuki Samurai

PostPosted: Tue Jun 12, 2012 10:07 pm    Post subject: Reply with quote



About 100degrees in one hit


Also got an ebay bargain on a brand new Bailegh angle finder, means I can get the plane of the bends perfect now . next to make is a couple stands on castors to support the ends of the tube during bending.



cheers

__________________________________
1990 Suzuki Samurai 1.9TDI (sold)
http://forum.difflock.com/viewtopic.php?t=53747

new truck build thread:
http://forum.difflock.com/viewtopic.php?p=595221#595221
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fourtrak craige
Articulating


Joined: 21 Mar 2012
Odometer: 863
Location: oxfordshire


1997 Daihatsu Fourtrak

PostPosted: Tue Jun 12, 2012 10:17 pm    Post subject: Reply with quote

Cool wow Cool

thats some good work there Smile

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muddy rapid
Just got MTs


Joined: 25 Aug 2011
Odometer: 150
Location: devon,tiverton



PostPosted: Wed Jun 13, 2012 5:11 pm    Post subject: Reply with quote

very impressed,might give you a bell in a few months for some bending on mine Very Happy
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aniesigh
Articulating


Joined: 15 Jul 2009
Odometer: 795
Location: north devon


1991 Suzuki Samurai

PostPosted: Wed Jun 13, 2012 10:05 pm    Post subject: Reply with quote

no worries, just had a cheque for £583 from the tax man so die might be here shortly Cool Very Happy
__________________________________
1990 Suzuki Samurai 1.9TDI (sold)
http://forum.difflock.com/viewtopic.php?t=53747

new truck build thread:
http://forum.difflock.com/viewtopic.php?p=595221#595221
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minimog
Off-Road Guru


Joined: 25 Nov 2004
Odometer: 1700




PostPosted: Wed Jun 13, 2012 10:35 pm    Post subject: Reply with quote

where are you getting your dies from as i need some new ones for mine
__________________________________
WHAT YOUR ASKED WHEN YOU OWN A MOG
"why have you put a merc star on that"
UNIMOG MOTTO
"IF IT CARNT BE FIXED WITH A BIG HAMMER"
IT MUST BE AN ELECTRICAL FAULT"
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aniesigh
Articulating


Joined: 15 Jul 2009
Odometer: 795
Location: north devon


1991 Suzuki Samurai

PostPosted: Wed Jun 13, 2012 10:37 pm    Post subject: Reply with quote

spooky i was just looking at the die set price lists from stakesys, they're who i was going to use unless you have any suggestions? £395 for a 7" rad 180deg 48.3mm die set, 375 for a 6" rad. can't decide which radius to get
__________________________________
1990 Suzuki Samurai 1.9TDI (sold)
http://forum.difflock.com/viewtopic.php?t=53747

new truck build thread:
http://forum.difflock.com/viewtopic.php?p=595221#595221
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minimog
Off-Road Guru


Joined: 25 Nov 2004
Odometer: 1700




PostPosted: Thu Jun 14, 2012 10:16 pm    Post subject: Reply with quote

I got mine from tubbella they are a little pricey but i dont think theres going to be much different between companys
__________________________________
WHAT YOUR ASKED WHEN YOU OWN A MOG
"why have you put a merc star on that"
UNIMOG MOTTO
"IF IT CARNT BE FIXED WITH A BIG HAMMER"
IT MUST BE AN ELECTRICAL FAULT"
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rockwatt
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Joined: 25 Jul 2007
Odometer: 1542
Location: North lincs



PostPosted: Sat Jun 16, 2012 10:16 pm    Post subject: Reply with quote

I got my dies from tubbella but they are jd2 and I don't think they fit in the JMR !
__________________________________
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aniesigh
Articulating


Joined: 15 Jul 2009
Odometer: 795
Location: north devon


1991 Suzuki Samurai

PostPosted: Tue Jun 26, 2012 10:06 pm    Post subject: Reply with quote

Pretty sure JD2 are different, JMR takes same as Pro tools so will end up getting from stakesys. still weighing up between 6 and 7" radius. anyone got any input? both have their pro's and con's but can't justify both at the minute.
being able to bend slightly thinner tube with the 7" doesn't really make much difference to me

__________________________________
1990 Suzuki Samurai 1.9TDI (sold)
http://forum.difflock.com/viewtopic.php?t=53747

new truck build thread:
http://forum.difflock.com/viewtopic.php?p=595221#595221
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Xpajun
Mud Obsessed


Joined: 22 Sep 2008
Odometer: 3245



1988 Mitsubishi Shogun

PostPosted: Tue Jun 26, 2012 10:14 pm    Post subject: Reply with quote

I can't help you with your decision but I would like to see your list of pros and cons regarding both sizes - or anyone else's for that matter
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aniesigh
Articulating


Joined: 15 Jul 2009
Odometer: 795
Location: north devon


1991 Suzuki Samurai

PostPosted: Tue Jun 26, 2012 10:38 pm    Post subject: Reply with quote

6" is cheaper
7" will bend thinner wall without deformation
6" will bend tighter
7" will bend bigger

think i'll go 6" as the places where a tighter radius will be advantageous are more important than the places where the bigger rad would be better

__________________________________
1990 Suzuki Samurai 1.9TDI (sold)
http://forum.difflock.com/viewtopic.php?t=53747

new truck build thread:
http://forum.difflock.com/viewtopic.php?p=595221#595221
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Xpajun
Mud Obsessed


Joined: 22 Sep 2008
Odometer: 3245



1988 Mitsubishi Shogun

PostPosted: Tue Jun 26, 2012 10:50 pm    Post subject: Reply with quote

I'm trying to remember back a long time but I believe the standard radius of a tube is 3 times it's own diameter - would have to get my machinery handbook out to check on that though Laughing Laughing
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350 Vortec
Just got MTs


Joined: 22 Mar 2011
Odometer: 169
Location: Ireland,East


1998 Nissan patrol

PostPosted: Wed Jun 27, 2012 9:24 pm    Post subject: Reply with quote

Nice work aniesigh
I just ordered 1.66 in 5.5 CLR and 1.9 in 6.5 CLR,250£ and 297£
I wanted as tight as possible and advised that that was it!!
Personally i think wider bends dont look great.
Will be doing a simular job to yours on the JD soon
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aniesigh
Articulating


Joined: 15 Jul 2009
Odometer: 795
Location: north devon


1991 Suzuki Samurai

PostPosted: Wed Jun 27, 2012 9:31 pm    Post subject: Reply with quote

yeah i think with the tighter bend i'll be able to get it to hug the body better, all the curves on my jimny body (or whats left of it) are fairly tight. also will mean the shock hoops will take up less space, going to order up tommorow!
__________________________________
1990 Suzuki Samurai 1.9TDI (sold)
http://forum.difflock.com/viewtopic.php?t=53747

new truck build thread:
http://forum.difflock.com/viewtopic.php?p=595221#595221
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mtm
Just got MTs


Joined: 21 Jun 2008
Odometer: 174
Location: newton abbot, devon


1982 Toyota Hilux

PostPosted: Sat Aug 11, 2012 9:04 pm    Post subject: Reply with quote

nice job there i went with the air hydro set up


__________________________________
2.4d;arb,truetrack lockers;twin trans case;rear discs;trans brake;5.29r&p;exo cage;full soft top;bobbed;38"swampers;winchbumper&x9;9"lift;crossover steering
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minimog
Off-Road Guru


Joined: 25 Nov 2004
Odometer: 1700




PostPosted: Sun Aug 12, 2012 12:02 am    Post subject: Reply with quote

Mtm have you used the bender yet as most bottle type jacks will not work when laid flat like in the pic
__________________________________
WHAT YOUR ASKED WHEN YOU OWN A MOG
"why have you put a merc star on that"
UNIMOG MOTTO
"IF IT CARNT BE FIXED WITH A BIG HAMMER"
IT MUST BE AN ELECTRICAL FAULT"
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Xpajun
Mud Obsessed


Joined: 22 Sep 2008
Odometer: 3245



1988 Mitsubishi Shogun

PostPosted: Sun Aug 12, 2012 6:49 am    Post subject: Reply with quote

minimog wrote:
Mtm have you used the bender yet as most bottle type jacks will not work when laid flat like in the pic



Depends where the oil pickup point is - all my bottle jacks will work on their side providing the pump is on the bottom
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350 Vortec
Just got MTs


Joined: 22 Mar 2011
Odometer: 169
Location: Ireland,East


1998 Nissan patrol

PostPosted: Sun Aug 12, 2012 9:09 am    Post subject: Reply with quote

doing a little work on my bender aniesigh and found that if i mount the ram as close as that to the fixxed arm the rod wont clear a 6.5 CLR at full stroke,my ram may be longer than yours but something to be thinking about,you can always repin but nice to use all stroke
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mtm
Just got MTs


Joined: 21 Jun 2008
Odometer: 174
Location: newton abbot, devon


1982 Toyota Hilux

PostPosted: Sun Aug 12, 2012 8:52 pm    Post subject: Reply with quote

yes all works fine i did have to blead the jack but as it was new i had to do it any way. i was going to go full hydro as they will work faster but this way worked out cheaper for me

i did make an alteration to the ram fixing so it will disconect from the bender arm then it will swing back when not in use




__________________________________
2.4d;arb,truetrack lockers;twin trans case;rear discs;trans brake;5.29r&p;exo cage;full soft top;bobbed;38"swampers;winchbumper&x9;9"lift;crossover steering
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aniesigh
Articulating


Joined: 15 Jul 2009
Odometer: 795
Location: north devon


1991 Suzuki Samurai

PostPosted: Sun Aug 12, 2012 10:05 pm    Post subject: Reply with quote

350 Vortec wrote:
doing a little work on my bender aniesigh and found that if i mount the ram as close as that to the fixxed arm the rod wont clear a 6.5 CLR at full stroke,my ram may be longer than yours but something to be thinking about,you can always repin but nice to use all stroke


I can nearly get full stroke out of my ram but not quite, actually using a different ram now, gone to double acting which i was trying to avoid doing all along as was trying to keep costs down and the S/A ram came with my pump, but its a much better setup in the end. looking forward to actually using it soon!

__________________________________
1990 Suzuki Samurai 1.9TDI (sold)
http://forum.difflock.com/viewtopic.php?t=53747

new truck build thread:
http://forum.difflock.com/viewtopic.php?p=595221#595221
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aniesigh
Articulating


Joined: 15 Jul 2009
Odometer: 795
Location: north devon


1991 Suzuki Samurai

PostPosted: Mon Aug 13, 2012 7:24 pm    Post subject: Reply with quote

MTM, where did you get your digital read out from? looks Cool

a more up to date pic of mine:


now double acting, but still got the push button to turn pump on so set direction then press button for go, means i can still move around to support tube/check all is well while bending and not restricted to standing next to the valve.





Got a nice new tube notcher too:



and bend-tech learning is coming along well


__________________________________
1990 Suzuki Samurai 1.9TDI (sold)
http://forum.difflock.com/viewtopic.php?t=53747

new truck build thread:
http://forum.difflock.com/viewtopic.php?p=595221#595221
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mtm
Just got MTs


Joined: 21 Jun 2008
Odometer: 174
Location: newton abbot, devon


1982 Toyota Hilux

PostPosted: Mon Aug 13, 2012 9:00 pm    Post subject: Reply with quote

the digital reader is a swag of road iten ive got a few of there bits now including the reach around arm for the baleigh tube nothcer

http://www.swagoffroad.com/Metal-Fabrication-Tools-_c_7.html

what bend tech software do you have

__________________________________
2.4d;arb,truetrack lockers;twin trans case;rear discs;trans brake;5.29r&p;exo cage;full soft top;bobbed;38"swampers;winchbumper&x9;9"lift;crossover steering
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aniesigh
Articulating


Joined: 15 Jul 2009
Odometer: 795
Location: north devon


1991 Suzuki Samurai

PostPosted: Mon Aug 13, 2012 9:06 pm    Post subject: Reply with quote

mtm wrote:
the digital reader is a swag of road iten ive got a few of there bits now including the reach around arm for the baleigh tube nothcer

http://www.swagoffroad.com/Metal-Fabrication-Tools-_c_7.html

what bend tech software do you have


Thats awesome cheers, will order some bits up from them soon i reckon!
went for Bend-tech pro

__________________________________
1990 Suzuki Samurai 1.9TDI (sold)
http://forum.difflock.com/viewtopic.php?t=53747

new truck build thread:
http://forum.difflock.com/viewtopic.php?p=595221#595221
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350 Vortec
Just got MTs


Joined: 22 Mar 2011
Odometer: 169
Location: Ireland,East


1998 Nissan patrol

PostPosted: Tue Aug 14, 2012 11:06 am    Post subject: Reply with quote

Looks good,you probably have space to move ram out on frame if need anyway
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