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Bending A Tube A Full 360 Degrees

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  • Bending A Tube A Full 360 Degrees

    I am currently making a portable dirt bike tyre changer. Unfortunately I need a tube ring to support the wheel.
    I have rung around but no engineering works in Brisbane can do this job so I decided to do it myself.
    I have a bender but it will only bend a tube to a 150mm diameter and I need it to be 400mm.
    I did some maths and determined how many bends and at what angles to achive my goal.
    This is my first attemp at this engineering problem.


    Ji
    Attached Files
    Grip it and Rip it

  • #2
    I Veed the joint and TIG welded the tube.
    To finish any tube welding you have to drill a small hole somewhere so the expanding gases can escape otherwise you will be trying to close that weld all day.

    Finished job.
    Very pleased with the result.

    Ji
    Attached Files
    Grip it and Rip it

    Comment


    • #3
      As usual, great work Ji. The ring looks great. Can you elaborate on the first picture you posted? How exactly did you prep. the tube?

      Gord
      http://gordsgarage.wordpress.com

      Comment


      • #4
        Hi Gord,
        Sure.
        All I did was draw a straight line along its length and marked the positions where the bends had to be made.
        There were 24 bends at 15 degrees which equals 360 degrees.
        The start and end points are determined by the diameter you require.

        Ji
        Grip it and Rip it

        Comment


        • #5
          I bent this 3/4" ali tube with a standard hand operated tube bender.
          The dies are cast iron and rough so I sanded them smooth before use.
          This not only prevents the rough surface from scratching the ali tube it also makes it easier to get the die to release the tube after the bend.
          To help release always grease the dies before bending.

          Ji
          Attached Files
          Grip it and Rip it

          Comment


          • #6
            With the same bender I bent this 3/4" square tube to well a square shape.
            This will be the base for a dirt bike tyre changer.
            The top ring tube supports the spokes so the tyre can be removed and installed.

            Ji
            Attached Files
            Grip it and Rip it

            Comment


            • #7
              Hi Ji, great looking bends on the square tubing, nice job! You showed only the top view of the bends, I am curious how the inside and outside curves look. Did the metal collapse at all? Keep posting the progress.

              Gord
              http://gordsgarage.wordpress.com

              Comment


              • #8
                I respect the man that can do metal working in Crocs much more than the man that simply wears Crocs. Well done.
                MillerMatic 252
                Spoolmate 200
                Diversion 165
                Spectrum 625 X-Treme
                Dayton 6" Miter Band Saw
                Delta Drill Press
                Bosch 10" Table Saw
                Bosch 12" Double Bevel Miter Saw
                Jet 5 Ton Chain Hoist
                Radnor O/A

                and this heavy duty table I made

                sigpic

                Comment


                • #9
                  As usual

                  Jigantor,

                  I follow most of your threads and have become a fan of your work. Nice job! As usual the project is well thought out yielding impressive results. I like the way you think.

                  As usual,

                  HAWK

                  Comment


                  • #10
                    Thanks Hawk,

                    Keep well mate.

                    Ji
                    Grip it and Rip it

                    Comment


                    • #11
                      Hi Gord,
                      The internal and external sides of the square tube are perfect.
                      The key was to smooth and grease the dies.

                      Ji
                      Attached Files
                      Grip it and Rip it

                      Comment


                      • #12
                        I made the square tube base just a little larger on purpose.
                        When bending tube unless you have a CNC bender the tube stretches slightly and that makes it just about impossible to get the exact size shape you require. By making the base 10mm larger that means all the vertical uprights will be at a slight angle in my case 5 degs. If I had tried to match the round ring top with the base and got it just slightly wrong one or two of my uprights would be on an angle and that would look terrable.

                        I find the art of clamping items to be welded more of an art than others give credit.

                        Two uprights tacked onto the base, it is now starting to look like something.

                        Ji
                        Attached Files
                        Grip it and Rip it

                        Comment


                        • #13
                          Hi Jigantor
                          Always great to look at your tradesmanship. Very professional.
                          Keep posting I really enjoy watching your posts.
                          Cheers Daniel

                          Comment


                          • #14
                            Hi Daniel,
                            Thanks for the kind words mate.
                            Will post again soon.

                            Ji
                            Grip it and Rip it

                            Comment


                            • #15
                              Clamp, wire brush and weld.
                              This is an industrial item so I am not going to sand and polish this, in fact I am not even going to clean off my fabrication marks.
                              I may want to attach a few more things to aid in changing a dirt bike tyre but it is now ready to start changing tyres.

                              Ji
                              Attached Files
                              Grip it and Rip it

                              Comment

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