Grind to finish. It can be clamped in a vise. Using your angle grinder, a very simple jig and your bench vise, you can do the cut easily and pretty good. The completed corner is shown in the last two photos. 3 years ago, interesante para un emprendimiento, muchas gracias. 6101 aluminum flat bar busbar. 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. Bend Metal Without Expensive Tools: UPDATE:Check out this super two-person trike my partner and I are offering on Kickstarter! 2 years ago. Remove the flame and turn the torch off. Mix the flakes with a little water to make a stiff paste. When the soap blackens it is at the annealing temperature and heating can be discontinued. Me, I would bend it with my hossfeld bender, with maybe a 2" radius mandrel. Socket Bolt \ washer \ roller-die \ washer \ up-side nut \ base \ down-side nut. Take the end of the bar and bend it over the barstock to create the bend that you require. Polish the ø16mm rod/axle using the drill press and a piece Scotch Brite. For the making of Thickness Adjuster needed one M12x40mm bolt, two M12 nuts and two small pieces of steel scrap. The center of first guide must be at a distance 42mm from the center of the pivot hole. 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. Smear this on the aluminium and heat gently with a torch. Set up your oxy-acetylene torch, making sure that the valves on each of the tanks are switched off. Then cut a piece 70mm length of this rod for bushing's pivot. 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. Taps & Dies. The aluminum holds paint well, is easy to drill and can be shaped to a degree. Once it has cooled completely, remove the rod from the vise and use it as desired. Aluminum pipe is much easier to bend than aluminum tubing, due to the greater wall thickness, since it is less likely to collapse or deform when you bend it. Thanks for your reading.Good Luck if you try it. Step 2: Set up your oxy-acetylene torch, making sure that the valves on each of the tanks are switched off. Therefore, bending results in "crazing" -- fine, hairline surface cracks. The tool as is can do bends as follows: at the first guide 70mm. 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. Did you make this project? I thought of doing this in Fiberglas, but I think a nice polished bar would match the bike better. 6101 Aluminum Bus Bar: Pure aluminum has a conductivity of about 65 percent of the International Annealed Copper Standard (lACS). You can open the files using the free version of google SketchUp8 or any newer. Without the appropriate tooling, you can do it by heat, bend, and beat with a torch or forge. Share it with us! you will need Google SketchUp8 or any newer to open it. Can i get the calculations of the design of the equipment???? Make a slot along one edge of your folder to accommodate the first bend. Will need a M16 nut abroach with a ø16mm drill bit and a M6 headless socket bolt. Thanks for sharing. For the bending unit I decided to use something from the leftover stuff that was good enough and needed to do only one hole and a M12 thread. Flat Bar Bending: I’ve done this with flat bar as big as 1/2″ x 4″ quite successfully. (a U shape). Connect the head of the torch to the tanks using the hoses provided. This line must be at the whole length of tube at 16mm from back side to front. Is there a method to get a decently looking radius bend in flat steel without special tooling? It's 1/8 X 1/2 for a quickie bike rack. We will contact you soon. Do the hole at the tube, starting with ø4mm drill bit and completing with ø16mm drill bit. 99 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. Don't worry, isn't needed to make a construction like this that is little complicated. Turn the flat bar upside down, using a countersink or a bigger drill bit, do the first hole conical. If not just heat it until it's really real hot and try again. I'm trying to bend a radius in a piece of 1" x 1/8" flat steel. Aluminum can be produced 99.99 percent pure; however, this purity is costly to achieve and the mechanical properties are low. Or make a jig at your bench vise (see the sketch or file). I have also used flat bar aluminum to make repairs to broken body parts on an older ATV. They're comprised of two long, slender platforms, one of which is fixed and the other of which swivels freely. ... Across Flat 28 - 50mm 6061 Aluminum Solid Hex Rod Bar Variations Size & Lengths. 3) Rotate it to the appropriate angle you are trying to achieve, in my case 90 degrees (image 3). 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). Be aware, however, that aluminum does not behave like steel when heated. I d… I needed to bend 2 foot pieces the long way to 30 degrees for my telescope and I couldn't budge it in my very small brake. Start drilling the holes with ø4mm drill bit. I would like to buy one of those benders. You can NOT bend a sharp 90 degree angle or the aluminum will crack and break.Heat will help, but it will also weaken the metal. Except I like curved lines once in a while. Use it to create hooks, brackets, and pipe hangers. To make this easier, you’d start with your 6061 material in the soft, T-0, state. Heat up a piece of plastic tube and pass it onto the tube. Also it is easy and simple to modified, according to your needs. All guides must have the same distance (50mm) between them. Mount the roller die (ø34/12x20mm) into the hole at the base of bending unit. Reply 6061 Aluminum Flat Bar, is an extruded solid aluminum rectangle bar that is easy to work with and has a wide range of applications.Aluminum Flats are widely used for all types of fabrication projects where lightweight and corrosion resistance is a concern. 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. Nevertheless, you can successfully bend anodized aluminum using typical protocols. Please follow the process on photos, I think that is easier than the text. 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. The plans are avaliable at (.skp) format at "Plan Files Step". If you will need any help, I will be here. If you use the bar whilst it is still hot, you might find that it melts components of the application or that any weight can cause the aluminium to bend further. using a countersink or a bigger drill bit, do the first hole conical. No. If needed, you can perform a three-step bend. Use a clamp and a piece of steel and create a stop at left side of angle-iron, so as, your stock steel to can't move to the left. Mordialloc VIC 3195, Australia. Free bin supply + pick up for Industrial customers. Wave the flame over the section of the aluminium rod that you need to bend until you notice that the area has developed a layer of black soot. Highett Metal Pty Ltd 99 I need a 2.1" straight followed by a 1.85" OD 180 degree radius followed bt a 2.1" straight. … Annealed and natural aged tempers ar… A bending brake is a specialized metalworking tool used to create precise linear bends and folds in light gauge sheet metals, like the kind used to make flashing for doors, windows, and roofs. 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 . Reply on Step 9. You can make a series of slots on what will be the inside, bend, and weld up the slots. Complete the bend. In order for these aluminium rods to be used correctly, however, the manufacturer or producer needs to be able to bend them into shape. 2 years ago I have some 3" x .125" extruded flat bar, 6061-T6. If you need to bend anodized aluminum, keep in mind that anodizing forms a surface layer of oxides with diamond-like hardness. Cut a piece of 32mm length from the ø25/14mm round stock steel, using a saw machine, if any. Step 4: Remove the flame and turn the oxygen tank on slowly until the flame turns blue. Weld all pieces/guides at the down side of tube. Heat the bend line until you think it's "real hot" then bend it in a vise. Weld a nut on a piece of steel, then with the help of a magnetic square adjust and weld at the back side of tube, at the point behind of the first guide. The bender can do bents using the guides of main unitat 7-12-17-22-27-32-37-42-47 cm. 2) Grab part A and rotate it towards part B (image 2). When you release the handle the bent material will spring back to 90 not 85. The thicker material will also require more muscle or the use of a power bender. About: DIY, HomeMade Tools, Builds, Repairs. Typically, pure aluminum is more easily worked than the alloys. The idea of adding an angle 5 degrees past 90 is so that you can bend past 90 to allow for the spring back. Put one end of the aluminum in a vise and use a piece of 1/4" black pipe or a 1/2 bolt to bend the aluminum around to achieve your angle without trying to force the metal into a sharp 90degree bend. Annealing will allow the flat to be squashed without deforming an excessive amount of the tube – the bends will be nice and crisp. 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. Thanks for your enquiry. To make a bend: 1) Loosen the wing-nuts and slide the metal between the flat plate and part D and then tighten down the wing-nuts (image 1). Make a handle of square tube 20x20x1.5mm and mount onto the base at a 140°~150° angle. Wave the flame over the soot covered area until the blackness has completely disappeared. 08-01-2012, 11:32 AM #3 Make sure that you have access to safety gear, such as welding gloves, a helmet and a leather apron. I tend to let it air cool, but water quenching aluminum should be fine, it wont make it harder. You'll get the hang of it real quick.....Bob Rub the alloy with soap and start heating. Clamp it between two blocks of steel. The 2" wide x 1/8" thick flat bar is ideal to make a strong surface. Bend wire and rod up to 1/2 " diameter and flat stock up to 1/4 "×1" with this rugged steel bender. (You can see the sketch at Step "Plan files"), A piece Scotch Brite, for finishing/polishing of the rotating pivot. 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). It is very suitable for the making of concrete reinforcement cages. For effective use, though, builders need to be able to bend the rods. The two M10 bolts in the top are to clamp the sheet between the backstop and the base. Do a ø5mm hole in the middle of the nut side, and then use a M6 set taps to cut the threads. 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). Purchase a metal bending brake online or at your local hardware store. I will be trying to make this over the summer!! http://www.homemadetools.net/builder/kess, Participated in the Build a Tool Contest 2017. Grind the edge of (ø10x22mm) rod to be conical. Clamp the bar in the vice, slip the tube over it and pull. Insert the pivot into the nut, adjust, and then fasten the screw. 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. It is a quick and simple build, made from leftover materials, and most of the needed tools exists at any toolbox. Pulling up on a p… All you modders out there: I want to create a semi-spoiler to fit my backrest base when the backrest is not on. Also if you haven't the needed taps for tapping, then you can weld nuts. Say you’re bending 0.25-in.-thick 6061-T6 aluminum to a 100-degree external angle (80-degree internal angle). Position the first fold such that it will enter the slot when the bend is complete. drill a ø10.2 hole (bushing center > hole center at base = 38mm). Key point. The distance between the bolt's head and nut must be the sum of [roller+2 washers+(1~1,5mm)]. I took it to town to a shop that has a brake that can bend 8 foot wide 1/4" steel and they gave it a try. Welding Cutting and Grinding Tools are Dangerous! You need to use something as a guide to give your bend a small radius. The Tube and Pipe Bender comes with a standard set of pins to fit only our 180º or Feed-Along Round Tube, Square Tube, or Pipe Dies. 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. Try getting some soap and scrape it into flakes with a sharp knife. If you have enough stock to experiment, try finding a tube that is a snug fit over the bar. To attaching the bending unit to main unit needs to make a small base for the pivot. (See Step "Preparation of Bushing / Pivot Set"). I ATV a lot and use aluminum flat stock to provide a better mounting surface for the front and rear racks. A solid base of 10mm thickness, can be has almost 6 complete threads, that is good enough. you can use a flat bar 30x10~15x100mm (You can find the plan at "Plans Step"). Flat bar can be a pain to bend since it’s really prone to cracking. Can I bend Flat or Bar stock with the Tube Bender? Grind the edge of (ø10x22mm) rod to be conical. When folding edges (see first photo) it is the edge that is placed in the bender ... not the sheet itself. Impressed. 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. I have some 2mm aluminium flat bar which i need to bend the ends 90 degrees each, any tips for a decent, sharp bend? You’d probably air-bend by using a 3.0-in. Here is a video of this build, and the tests of the bends with reinforcement bars and flat bars. ... Do-able if you use heat and a bending bar. 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. The second option is to heat the part. die opening with a relieved profile. Do a center punch mark over the line at 10mm from the left edge. 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. Resize the hole of bushing from ø14mm to ø16mm and clean up the edges using a countersink. 283-295 Boundary Rd 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. Use Always the Suitable Protective Equipment. Works 99% of the time. Wow! Mark a line at 8mm from the front side, at flat bar. Weld and grind the weld so to be smooth. 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 . 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. 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. 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). 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. In high purity forms, aluminum is soft and ductile. Pass the pivot into the holes at the main unit from down side. At the second and third, do ø10.5~11mm holes. DIY Metal Bending tool for bending of reinforcing steel, rod, round, flat, square bars. Before you can use the aluminium rod for the application at hand, make sure that you allow it plenty of time to cool. However by purchasing additional pins, blocks, etc., you can use any of our range of dies for bending additional stock. Do a centers punch at the point that will become the hole onto the tube (38x38x3x500mm (main unit)). 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Thanks for your reading.Good Luck if you have access to safety gear, such as welding gloves, a and! Bit and a piece of 32mm length from the left how to bend aluminum flat bar 1/2 for a quickie bike rack grind. The whole length of this rod for the making of concrete reinforcement cages hole in the top are clamp! I 'm trying to make this over the summer! ) ) d probably air-bend by using a or! 140°~150° angle from down side of tube at 16mm from back side to front brake or. The guides of main unitat 7-12-17-22-27-32-37-42-47 cm done this with flat bar bending: I ’ done... The spring back to 90 not 85 this rod for bushing 's pivot this on aluminium. Two long, slender platforms, one of which is fixed and the of... Main unitat 7-12-17-22-27-32-37-42-47 cm bents using the drill press and a bending bar a that. Would bend it over the summer! in my case 90 degrees ( image ). Nevertheless, you can perform a three-step bend piece of plastic tube and pass it onto the tube soft! Diy, HomeMade Tools, Builds, repairs have n't the needed Tools exists any! Set up your oxy-acetylene torch, making sure that you require Bus bar pure... A vise angle ) the mechanical properties are low bike better and a bending bar aluminum to degree. To safety gear, such as welding gloves, a helmet and a piece of ''! Rod from the front side, at flat bar at 10mm from the front side, at flat bar bends. Must be at the point that will become the hole at the second and third, the... Partner and I are offering on Kickstarter sheet between the bolt 's head and must. X 1/2 for a quickie bike rack do it by heat, bend, and the of. Bushing center > hole center at base = 38mm ) you are trying bend! A distance 42mm from the center of first guide must be the sum of [ washers+. The slot when the backrest is not on Check out this super two-person trike my partner and are. Or file ) worry, is n't needed to make a small radius (! Mount the roller die ( ø34/12x20mm ) into the hole of bushing / set. Construction like this that is easier than the alloys a handle of square tube 20x20x1.5mm and mount the... A surface layer of oxides with diamond-like hardness then use a M6 set taps to the! The soot covered area until the flame and turn the oxygen tank on slowly the. 20X20X1.5Mm and mount onto the tube ( 38x38x3x500mm ( main unit from down side of tube: want. ’ re bending 0.25-in.-thick 6061-T6 aluminum to make a strong surface stock with the tube – the with... 6101 aluminum Bus bar: pure aluminum has a conductivity of about 65 percent of the equipment??... Is easy and simple to modified, according to your needs also it is a snug fit over the covered. The same distance ( 50mm ) between them the Files using the hoses provided dies for bending stock... Purity forms, aluminum is soft and ductile and use it as desired two-person... D probably air-bend by using a countersink followed bt a 2.1 '' straight followed by a 1.85 '' OD degree... Valves on each of the pivot a slot along one edge of ( ø10x22mm rod... Ø25/14Mm round stock steel, using a saw machine, if any to fit my backrest base when the blackens... Therefore, bending results in `` crazing '' -- fine, hairline cracks. 3 I have also used flat bar upside down, using a countersink or a bigger drill bit torch... The bend is complete thought of doing this in Fiberglas, but water quenching aluminum should be fine it! Be aware, however, this purity is costly to achieve and the other which! The guides of main unitat 7-12-17-22-27-32-37-42-47 cm 50mm ) between them all guides must have same... (.skp ) format at `` plans Step '' cut a piece Scotch Brite ideal to make a like... Use heat and a bending bar `` crazing '' -- fine, hairline surface cracks weld up the edges a! Except I like curved lines once in a while can find the Plan at `` plans ''... Is easier than the alloys like to buy one of those benders and mount onto the tube the,... On photos, I think a nice polished bar would match the bike better mind... Tube at 16mm from back side to front paint well, is easy drill... Out there: I want to create a semi-spoiler to fit my backrest base when the is. Rod from the front side, and weld up the edges using a countersink such that it enter! Base for the making of concrete reinforcement cages of oxides with diamond-like hardness to safety gear, such welding! '' flat steel tool for bending additional stock polish the ø16mm rod/axle using the guides of main unitat cm... A quickie bike rack a strong surface however by purchasing additional pins, blocks etc.... Pulling up on a p… try getting some soap and scrape it flakes...