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Old January 1st, 2010, 06:26 PM   #1
Haggar
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Default Home built Bender (Got Trikes bender)

I'll start a thread to detail the bender that I'm building. I got the plans a long time ago, but never got around to building it. This is the well known 'got trikes' bender, its had pretty good reviews from those who have built them.

I have used a manual ProTools 105 before, and don't really like it, for my small space. It takes a lot of space to swing the handle, and requires studs into the concrete to bolt it down. You also get a serious workout swinging that handle all day to bend a cage, its a lot of physical labor.

This one will be self contained, and use an air-over-hydraulic ram to do the bending.

Cost wise, its still around $250 or so, which isn't that much cheaper than basic pro-tools. But it will be hydro, and portable, and bends in a vertical plane, which I like.

It will look something like this when its done. There will be some modifications to it, when its done. There are newer, better versions of the plans that have some nice improvements, I don't feel like buying the updated plans, but I will do some of those updates I think.




The main frame is built from 2x2 square tube. First, I built the die puller, which is the most complex piece to machine. Those are made from 2.5" x 0.625" cold rolled 1018 flat stock. I spot welded the arms together in a few places to drill both at once so they will match up.



Sharp drills, lots of cutting fluid, and a consistant feed rate and you get nice big spirals. The mill is much nicer than my drill press, no runout, no chattering. They are nice a shiny, too, not straw or blue color, so not getting too hot.



Here are the finished arms, with the hardened shafts that will be for the pivots. The block between them will be welded in place, to make the puller one piece.




Bunch of smaller pieces as well, for holding the ram to the frame, the die puller to the frame, etc.

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Old January 1st, 2010, 06:28 PM   #2
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Here's the frame, all the pieces are cut to size:



Here's the ram, works pretty slick, it will be nice to not have to do anything but push the button. Its just an air-over-hydraulic long ram jack from harbor freight. Because I used the air operated ram, I had to modify the plans a bit, as its too wide to fit through the supports as originally planned. No biggie, just canted one side out a bit.



This thing is going to be a beast. There's around 110 lbs of steel tube, then the die puller, die set, pins, and the ram. It'll be around 150-175 lbs when its done. I'm going to put it on wheels with leveling screws.
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Old January 1st, 2010, 06:31 PM   #3
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Worked more today, to get the uprights drilled. Each hole is for the pin location for a different size die. I'm quite impressed with how well the harbor freight silver & demming bits work, i've had these for over a year and they cut great. 120 rpm and lots of lube helps.

Here I'm laying out the hole locations:



next is getting them fixtured down to the table. The solid rod in the chuck is for checking that its square to the travel of the table. You run it all the way one way, and measure the distance between the rod and the work with a feeler gauge. THen travel all the way the other way, and it should be exactly the same gap. Then you know you are travelling perfectly in a straight line. (If I had a correct setup for a dial indicator, thats a better way to do it, but I'm working with what I have....)



And away we go. First the pilots, then the 7/8" holes. That is 4" thick, used every last inch of the drill bit to get all the way through both pieces. (Like the arms, these were squared up and welded together, to be square). Having the 5" stroke on the mill is nice for work like this.



And all done:

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Old January 1st, 2010, 06:31 PM   #4
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Frame tacked together:



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Old January 1st, 2010, 06:32 PM   #5
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OK, just about complete. Here's where I got to today, pretty much all together, just need to finish weld it.



You can see that the piece of tube in there is angled downward. It should be more or less level, something that the guys warned about in the build threads on Pirate. YOu can see it better in this shot better. So the remedy is to cut and move the two tabs upward that hold the main pivot for the die. So I did that, now its more or less level. I made sure that the puller strap can be fit in place.



So, I just need to finish weld it, hopefully tomorrow. I want to put it on casters, and put levelling screws on each leg as well. Once its warmer, I'll go through it, maybe fill in all of the open tube ends, grind welds smooth, paint it, etc.

Here's a video of it running. It doesn't operate real fast, but thats OK for me, not doing production work, and I like going slow with bends, so that I can get the angle precise. Its an air powered ram so just plugs into the air compressor.


The tube isn't strapped in, so its not actually bending, just going through the motion...
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Old January 1st, 2010, 06:42 PM   #6
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I built the same bender last winter. I love it. I put 4 locking casters on it so its mobile. I also put a tray on the one side to hold the pins, angle gage, and digital level. This is kinda handy, keeps everything right where you need it. When i was done i sprayed the whole thing with a can of spray on bedliner, durable and doesn't look bad either. Just some ideas hope this helps. Looking good.
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Old January 1st, 2010, 06:47 PM   #7
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Looks good! If you havent already planned on it, the holes that hold the adjustable slip shoe get ovaled out easily on the pro-tools arms and the arms I have look to have a little more meat between the holes. Something that could help buy you some time is to make a couple plates of whatever thickness, 1/4-1/2" to double up the adjustment hole area.

I also plan to remake the main arms on mine because the 5/8" thickness wasnt enough to keep it from tweeking while bending 1.75x.25". The new ones will be probably 1" thick, just because I can.
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Old January 1st, 2010, 06:50 PM   #8
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I've used mine a few times, holds up to 2"x1/8wall.

If you come up with a good way to measure the angle of the dangle, post it!

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Old January 1st, 2010, 06:52 PM   #9
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Thats the one Ironman uses and it works well. Nice build. You do know the follow bar is backwards right? I'm assuming it was just for your demonstration video.
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Old January 1st, 2010, 06:55 PM   #10
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i want one. anybody sell it complete? i cannt see it being that much to build. i know that the labor might cost a bit.


ill be collecting my state pay check soon (MARVIN). i am going to need something to keep me from going stir crazy.

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Old January 1st, 2010, 06:59 PM   #11
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Quote:
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Thats the one Ironman uses and it works well. Nice build. You do know the follow bar is backwards right? I'm assuming it was just for your demonstration video.
The follower die? Yeah, I had it in and then looked at the pics and saw it was backwards. I have it correct now.


LOL, by the way, yes, I know the garage is messy. I have a 20x20 garage, with my CJ-6 build, a 5.3V8 on a pallet, my quad+plow, plus mill, drill press, cherry picker, welder cart, air compressor, press, belt sander, tool boxes, etc. I have no room to do anything. Building a pole barn next summer.
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Old January 1st, 2010, 07:05 PM   #12
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Originally Posted by spr_chicken View Post
i want one. anybody sell it complete? i cannt see it being that much to build. i know that the labor might cost a bit.

ill be collecting my state pay check soon (MARVIN). i am going to need something to keep me from going stir crazy.
Costs are about this:

$90 for the 2x2 tube.
$60 for the ram
$35 for shafts, collars, and bolts
$10 for small misc steel pieces you'll need (short piece of 1" tube, short piece of 2.5" square tube)
$30-40 for the flat bar for the arms.

I have between $200-$250 into it, and that die was $285. (1.75" x 6clr-240*). It isn't cheap, necessarily. If you have a bunch of steel laying around, you could do it cheaper, or if you used an manual ram, too. If you just borrow the one off your cherry picker, its free, since you aren't going to use both at the same time.

Don't use hot rolled for the arms, they don't last from what I've heard.

I don't think anyone sells them built, as then it ends up being the same cost as a manual 105.
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Old January 1st, 2010, 07:07 PM   #13
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Quote:
Originally Posted by Haggar View Post
The follower die? Yeah, I had it in and then looked at the pics and saw it was backwards. I have it correct now.


LOL, by the way, yes, I know the garage is messy. I have a 20x20 garage, with my CJ-6 build, a 5.3V8 on a pallet, my quad+plow, plus mill, drill press, cherry picker, welder cart, air compressor, press, belt sander, tool boxes, etc. I have no room to do anything. Building a pole barn next summer.
don't sweat it. I gotta 32 x 48' barn and its worse than yours. Just don't want to waste valuable build time on CLEANING thats for women
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Old January 1st, 2010, 07:19 PM   #14
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hey man nice job on the bender. I was wondering where you got all the materials for ur bender manily the shafts collers ect. thanks
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Old January 1st, 2010, 07:57 PM   #15
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where did the die come from ive been going to buy one but i have lots of spair time lately and most of that steel laying around. nice work
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Old January 1st, 2010, 08:00 PM   #16
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where did the die come from ive been going to buy one but i have lots of spair time lately and most of that steel laying around. nice work
you wanna build 2 let me know
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Old January 1st, 2010, 08:35 PM   #17
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I got my die from TMR customs

http://www.tmrcustoms.com/store/inde...roducts_id=380

You can get a better price if you talk to him through pirate.

shafts and collars, you can get from mcmaster carr or similar. Steel, well, go toy ur steel yard. The arms are 2.5x0.625 bar stock, cold finished 1018 steel, if you can't get it from your steel yard in a small drop, then you can go to speedymetals.com and get it. Can get some of the small pieces there as well.

I still need to go in and make a set of spacers for the ram, which will be made from 1" x 0.625" ID DOM tube that I have a chunk of. I have to turn them on my lathe to fit into the 0.875" holes in the die puller arms. They just keep the ram centered and spread the load across the bolt better.
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Old January 1st, 2010, 08:37 PM   #18
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you wanna build 2 let me know
Really, you don't need anything fancy, just a drill press and a welder, if you take your time and are careful.

I did all of the holes on my mill, which has a lot less runout compared to a (bad) drill press. The holes were right to size, and had zero slop on the pins. YOu then realize that the dies have their holes a little oversize and you'll never get it welded absolutely perfectly on line, and have to open the holes a bit with a die grinder to get the pins to go in and out nicely.
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Old January 2nd, 2010, 02:44 AM   #19
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I have access to a full machine shop looks pretty simple. Thanks for the info
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Old January 3rd, 2010, 09:15 AM   #20
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looks good!
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