Aluminum is a lightweight metal with a strong weight-to-strength ratio that makes it useful in many manufacturing processes from auto aftermarket installations such as roll bars to the construction of hiker backpacks. Follow these instructions to get the right sort of bends: Step 1: Place the rod into a tabletop vise, making sure that the section you need to bend is positioned slightly higher than the vise (this allows you to make the bend without indenting the top of the arc with the vise). you can use a flat bar 30x10~15x100mm (You can find the plan at "Plans Step"). Wave the flame over the soot covered area until the blackness has completely disappeared. I would like to buy one of those benders. die opening with a relieved profile. If you will need any help, I will be here. The tool as is can do bends as follows: at the first guide 70mm. on Step 9. The bender can do bents using the guides of main unitat 7-12-17-22-27-32-37-42-47 cm. Use it to create hooks, brackets, and pipe hangers. Bending is a delicate and demanding process most of the time and common fabricating processes require a degree of formability that make your choice of proper alloy critical.Depending on designation, alloys go through different heat treatment procedures during production. In order for these aluminium rods to be used correctly, however, the manufacturer or producer needs to be able to bend them into shape. You’d probably air-bend by using a 3.0-in. Also if you haven't the needed taps for tapping, then you can weld nuts. Using your angle grinder, a very simple jig and your bench vise, you can do the cut easily and pretty good. Be aware, however, that aluminum does not behave like steel when heated. Bend wire and rod up to 1/2 " diameter and flat stock up to 1/4 "×1" with this rugged steel bender. Polish the ø16mm rod/axle using the drill press and a piece Scotch Brite. Remove the flame and turn the torch off. Needed 30mm space at the edge of the vertical sides, so the bending unit to can rotate and rounding the corners at the horizontal sides. I'll be bending the metal using a jig just like the one in this 'ible.I'm a big fan of Atomic Zombie's builds. 283-295 Boundary Rd 6101 aluminum flat bar busbar. Use Always the Suitable Protective Equipment. Typically, pure aluminum is more easily worked than the alloys. That will produce close to uniform bends, and is very repeatable once you figure out how close to the vice the tube needs to be when you start bending. Say you’re bending 0.25-in.-thick 6061-T6 aluminum to a 100-degree external angle (80-degree internal angle). The two M10 bolts in the top are to clamp the sheet between the backstop and the base. Making a small and simple addition we can double the range of bends as follows: For this addition will need a flat bar 30x3x100mm ant a piece of rod bar ø10x22mm. Do a centers punch at the point that will become the hole onto the tube (38x38x3x500mm (main unit)). drill a ø10.2 hole (bushing center > hole center at base = 38mm). 2 years ago. Please follow the process on photos, I think that is easier than the text. Will need a M16 nut abroach with a ø16mm drill bit and a M6 headless socket bolt. (See Step "Preparation of Bushing / Pivot Set"). When folding edges (see first photo) it is the edge that is placed in the bender ... not the sheet itself. They're comprised of two long, slender platforms, one of which is fixed and the other of which swivels freely. Do a center punch mark over the line at 10mm from the left edge. The main unit is a simple tube (38x38x3x500mm).I have made the pivot holes at an earlier step (Preparation of Bushing / Pivot Set) but before the installation of guides need to do some cuts at the edge of tube. Turn the flat bar upside down, using a countersink or a bigger drill bit, do the first hole conical. Step 4: Remove the flame and turn the oxygen tank on slowly until the flame turns blue. Reply Flat Bar Bending: I’ve done this with flat bar as big as 1/2″ x 4″ quite successfully. For flat bar, the mandrel will either have a groove for the stock to fit in or have followers to hold the stock in plane. When the soap blackens it is at the annealing temperature and heating can be discontinued. Make a handle of square tube 20x20x1.5mm and mount onto the base at a 140°~150° angle. You can open the files using the free version of google SketchUp8 or any newer. … Me, I would bend it with my hossfeld bender, with maybe a 2" radius mandrel. Cutting disk ø115 x 1mm – (ø4 ½” x 0.04”) or ø125 x 1mm – (ø 5” x 0.04”), Saw machine (optional but helpful if any). Once it has cooled completely, remove the rod from the vise and use it as desired. Set up your oxy-acetylene torch, making sure that the valves on each of the tanks are switched off. I'm trying to bend a radius in a piece of 1" x 1/8" flat steel. Taps & Dies. A solid base of 10mm thickness, can be has almost 6 complete threads, that is good enough. Mount a piece of angle-iron, in the vise, Place the steel into the angle-iron, so as the cutting point to be just next to end of the angle-iron. Grind to finish. (a U shape). Weld and grind the weld so to be smooth. I have some 3" x .125" extruded flat bar, 6061-T6. Key point. The idea of adding an angle 5 degrees past 90 is so that you can bend past 90 to allow for the spring back. Free bin supply + pick up for Industrial customers. But you should be able to bend it in a vise, with a cheater bar- maybe a piece of pipe about 3 feet long that slips over your bar. The thicker material will also require more muscle or the use of a power bender. It can be clamped in a vise. The distance between the bolt's head and nut must be the sum of [roller+2 washers+(1~1,5mm)]. 08-01-2012, 11:32 AM #3 Take the end of the bar and bend it over the barstock to create the bend that you require. 2) Grab part A and rotate it towards part B (image 2). Drill bits: ø4mm, ø5mm, ø10mm, ø10.2mm, ø10.5mm, ø12mm, ø16mm, 1pcs Round stock steel ø25/14x32mm (bushing), 1pcs Round stock steel ø34/12x20mm (roller die) if it is from hardened steel will be much better, 1pcs Rod ø10x600mm or 9pcs x57mm & 1pcs x22mm, 1pcs Flat bar 30x10~15x100mm (bending unit), 1pcs square tube 20x20x1.5mm or heavier (handle), Hex Socket Bolts: 1pcs M12x60mm, 1pcs M10x30mm. For the making of Thickness Adjuster needed one M12x40mm bolt, two M12 nuts and two small pieces of steel scrap. Cut a piece of 32mm length from the ø25/14mm round stock steel, using a saw machine, if any. Step 3: Turn the acetylene tank on and light the gas at the end of the torch using a striker; wait for the orange-red flame to flare. Pass the pivot into the holes at the main unit from down side. I have used the extra (down-side) nut because my base isn't solid and each side of 4mm thickness, can has only 2 complete threads (the pitch of M12 coarse thread is 1.75mm). Share it with us! All you modders out there: I want to create a semi-spoiler to fit my backrest base when the backrest is not on. Pulling up on a p… Step 5: Place a metal barstock that has about the same curvature of bend that you wish to create against the section of straight rod that you need to bend and clamp into place. using a countersink or a bigger drill bit, do the first hole conical. Nevertheless, you can successfully bend anodized aluminum using typical protocols. The center of first guide must be at a distance 42mm from the center of the pivot hole. Rub the alloy with soap and start heating. The completed corner is shown in the last two photos. For instance, you can perform a 2-degree bend in front of the bend centerline, a 2-degree behind the bend, and then an 86-degree bend in the center. Is there a method to get a decently looking radius bend in flat steel without special tooling? The plans are avaliable at (.skp) format at "Plan Files Step". Remington Industries 0.25X3.0FLT6061T6511-24 1/4" x 3" Aluminum Flat Bar, 6061 General Purpose Plate, 24" Length, T6511 Mill Stock, Extruded, 0.25" Diameter 5.0 out of 5 stars 17 $23.99 $ 23 . You'll get the hang of it real quick.....Bob As aluminium is a lightweight metal that possesses an exceptional weight-to-strength ratio, it is commonly formed into rods that are used in a variety of applications, from cars to backpacks. Don't worry, isn't needed to make a construction like this that is little complicated. You can find your bend allowance with the following formula: (π/180) x B x (IR + K x MT) = bend allowance (BA), where B is the angle complementary to your desired bend angle (1 to 180 degrees), MT is the thickness of the material, IR is the inside radius, and K is the K-factor. Using the end of the angle-iron as guide, slide the cutting disk over it, and rotating the stock steel by hand, do the cut, (the cutting disk is not needing to pass across). I have use a disk saw machine to cutting the piece for the bushing, but if you haven't such tool, isn't critical or prohibitive. Also it is easy and simple to modified, according to your needs. Remington Industries 0.25X3.0FLT6061T6511-24 1/4" x 3" Aluminum Flat Bar, 6061 General Purpose Plate, 24" Length, T6511 Mill Stock, Extruded, 0.25" Diameter 5.0 out of 5 stars 17 $22.99 $ 22 . 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