2" Square tube bender

[norbie454]

I tried to build a 2" square tube bender using my wood splitter but I seem to be doing more crushing rather than bending. Not sure but I am thinking I need a larger radius push die with a more robust center section and maybe some side plates. if anyone has done this before and been through the growing pains with any suggestions I would greatly appreciate it. Here are a few photos to show what I am up against.

 

[Rustyiron]

I think your on track with a bigger radius and side plates. 2" tube is asking for a lot of stretching on 3 sides. I'm not sure it can be done without one side being disformed, even my factory "ROPS" is misformed on the inner side of the radius. I wonder how much structural integrity is lost with this?
I have bent tube like this by slicing 3 sides (every 1/2" or so) with an abrasive chop saw and bending/welding then a heck of a lot of grinding.

 

[kenord]

I built a die for 1 inch it worked ok but it took a lot of trial and error,
It is 6 inch with (if I remember right) about 3/8 sides and a 1/4 inch hump in the center, I turned it on my lathe , I saw on u tube some people just weld a1/4 inch rod in the center, It starts the crush that is required , so the metal has some place to go, the sides of the die, keep it from expanding. I don't think I could have gone any smaller than 6 inch , or just would have crushed the tubing,
for 2 inch a lot bigger radius would be required,and at least 1/2 inch or larger hump in the center, How thick is the tubing your trying to bend?
I was bending thin wall , I think .063 , I tried bending by hand , but ended up using a hyd cylinder.
I was bending a full 90 degrees. there are quite a few examples on u tube , even using plywood as a die, good luck and let us know how it works out.
have fun, stay safe,
Rich

 

[vidio1]

Look at the name brand tube benders for their minimum die radius. There is a minimum radius for all tubing depending on type and thickness. Take those as an extreme minimum, I.E. go a couple sizes bigger if you can as your bender design is less than ideal.

 

[davedj1]

II think you will have to contain the two sides as well. Instead of pressing it, try like a tubing bender and draw it through.
Introduction to Square Tube Bending @ Trick-Tools - YouTube
Hand bending 1" square 18 gauge steel tubing to a 4-1/2" radius - YouTube

 

[Redlands Okie]

Not a expert on tube bending but i have seen several deals like this where they fill the tube with sand to help prevent the crushing.

 

[norbie454]

Thanks for the info the video shows me where I need to make improvements I will make a new push die this week and let you all know if I get better results.

Fear of the unknown is greater than fear of the event.
Norm David 1972

 

[norbie454]

I made a new die and got the 2" square tube with .125 wall to bend the 2 identical pieces are bent at 30' and the longer piece is bent at 40' I have a photo of the ATV log arch welded I painted it today and will post later under a new heading of ATV log arch so if you are interested stay tuned

 

[Billrog]

Nice job. Thank you for the thread I've bent a bit of square tubing but never neat, now I've learned something for next time from the posts here.

 

[Raspy]

Norbie,

That is really a nice job! I've seen square tube with those kind of bends but never knew what the bender looked like. All of that was done very accurately.

 

[weldingisfun]

I made a new die and got the 2" square tube with .125 wall to bend the 2 identical pieces are bent at 30' and the longer piece is bent at 40' I have a photo of the ATV log arch welded I painted it today and will post later under a new heading of ATV log arch so if you are interested stay tuned

Nice work norbie454. It that to move goose neck trailers with a bumper pull hitch? Also, FYI you can make the degree sign ° by holding down the ALT key while typing 248 on the number keypad.

 

[Rustyiron]

I made a new die and got the 2" square tube with .125 wall to bend the 2 identical pieces are bent at 30' and the longer piece is bent at 40' I have a photo of the ATV log arch welded I painted it today and will post later under a new heading of ATV log arch so if you are interested stay tuned

That's nice!
Have you seen the "tools you've made" thread? A short post there with some pics and an explanation would kinda catalog your tool in a place that has many good ideas for future reference for others.:thumbsup:
Looking forward to see your ATV log arch!

 

[Big Barn]

Really nice job, norbie!! I'm glad you got it figured out.

Terry

 

[davedj1]

Nice work! The only suggestion I would have is to cap the front ends of the pieces with the wheels on them. If water gets in there and freezes it will blow right apart. Do you have a video or could you take one bending a piece? It will help us out. Thanks

 

[norbie454]

Posting my 2" square tube bending project under ***ATV log arch*** only a 4 second video but it will show the end results thanks for the input guys.

 

[norbie454]

Lakes region Maine Rustyiron you are right around the corner from me I live in Otisfield Maine. I just posted my ATV log arch with a short video under this same build it yourself section. I will post my dies under the tools you've made thread, thanks. I just looked and could not find the tools you've made thread.

 

[Xfaxman]

Lakes region Maine Rustyiron you are right around the corner from me I live in Otisfield Maine. I just posted my ATV log arch with a short video under this same build it yourself section. I will post my dies under the tools you've made thread, thanks. I just looked and could not find the tools you've made thread.

Click this to post there: http://www.tractorbynet.com/forums/newreply.php?p=4616226&noquote=1

 

[Rustyiron]

Norbie, yes we are real close.
Thanks Xfaxman for the proper link, I did not give norbie the exactly correct name.

 

[Renze]

Most square tube benders are designed to fold the excess material of the inner flange into the tube and bend only the radial flanges, while supporting the flanges on both sides to prevent them folding outward.

The only other option is like they do when bending trumpets and other brass instruments: Fill with mud, freeze solid, then bend.