How to Bend Tube with a Pipe Bender!

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welcome to another episode guys today we

are going to be attempting to turn this

high fender into a tube bender and the

reason or main motivation for doing it

is that a pipe bender is very cheap in

comparison to a to better I'm sure to

better will cost you upwards of about

five hundred dollars and that's probably

without all the different diets for

betting different sizes to where is this

particular pipe bender including all the

different diets

I think cost me about $100 brand new and

so you can see there's a big difference

there in price and it's nice to also be

able to use one tool to do multiple

things and so then you may ask yourself

why for can we just put the tube in the

pipe bender and it'll Bend I mean after

all tubes and pipes or volts just round

hollow profiles

well the difference lies within how

those round all the profiles are

actually measured and designated and so

if you take a pipe for example its

measured based on a nominal ID and the

wall thickness is called the schedule of

the pipe and so when you compare that to

a tube which is measured based on the

outer diameter of the tube and the wall

thickness you get this different system

in measurement for both these stadium

round hole profiles and so if you take

this pipe bender and say you use a one

inch pipe diet and you take your one

inch tube and you put it in the die

you'll notice that there's quite a bit

of play in there because of these

different measuring systems the one inch

pipe is not equivalent to the one inch -

and then so you might think okay well

I'll just grab a smaller die

pipe dies and use it with the larger

diameter - even that doesn't work

because the difference is a measurement

system we still get a lot of slop inside

the die and so what that ends up

happening inside your pipe bender is

when you put the tube in there with all

the slop and you go to bed get the -

eventually kinks right in the center

then this kink gives the pipe bender its

nickname when bending - as a tube tinker

today today we're going to try to modify

this pipe bender here to get rid of that

kinking that happens when you go to bank

two and so this concept isn't new I

don't claim to have invented this or

anything I've seen a lot of

modifications done online to varying

degrees of success and so while the

general concept isn't mine this

particular design is mine and so we're

going to zoom in here and get a better

picture at what I've done here so taking

a closer look at this assembly you'll

notice that at the core of the assembly

is a pipe dye and the size of this pipe

dye will be the same size as the two

that you're trying to bend so for

example if I'm trying to bend at 1.25

inch diameter tube I'm going to be using

a 1.25 inch pipe dye now like I

mentioned earlier that's going to result

in a lot of sloppy inside if I just put

the two right in there so let's take

this apart and I'll show you how I'm

going to plan on eliminating that slop

with this assembly so right now I'm on

threading this top screw and that will

release this clamping piece and you can

see that I've made this clamp piece out

of a 1.25 inch pipe and what this means

is that on the inside the ID of this

pipe originally had a nominal 1.25 inch

diameter inner diameter and so this

should fit very snugly onto the 1.25

inch tubing because because that's

measured on the outer diameter and what

you'll also notice on the inside is that

I took a 1.25 inch nominally inner

diameter pipe I bent it to conform to

the shape of the die so I use this very

diet itself to bend this tube and so it

obviously matches the profile perfectly

and then all I did was I just cut it in

half to provide a channel and this

channel is what the tubing should follow

and a fence and so it should also

provide it with a nice very tight fit on

the inside to eliminate that slop so

essentially all I've done is just

created some sort of spacer if you'd

like to call it that or a shim in a

sense to take up the slop

so that takes up the slap on the bottom

this takes up the slop on the on the top

and so when you slide them in together

and you thread down on this top piece

here this should clamp the tubing into

place and hopefully take up any space

that would allow that tubing to kink

when it's bent because one of the tubing

kinks at the top what does the popping

is it expands outwards so we're

essentially just taking up that space to

prevent it from expanding outward and

then of course this entire assembly is

just mounted to the actual die itself

and that way when you tighten up on this

piece here it just tightens against the

die and you have one solid piece holding

the tube in to play

one other thing to take note of here is

different hole locations for the

different pipe ties and so this single

assembly should work for all the

different pipe ties that I have and the

only pieces that I would have to make to

10 different sizes of tube

I'll have to of course get different

pipes bend them and cut them like this

and make a new clamp to account for the

different outer diameters of say a

different tube size if I wanted to bend

a a 1.75 inch tube I would have to use

the 1.75 inch nominal ID pipe in order

to clamp it and to eliminate that space

and so it's just an extra shot here you

can see down the middle exactly where

the cubing will go and so finally one of

the modification that I seem done to the

pipe benders to turn them into to

benders is now the pipe benders come

with these tapered rollers off the top

here and I have seen people replace

these with something like this and so I

also went ahead and made these two again

I I'm bending 1.25 inch tubing so I used

1.25 inch nominal inner diameter pipe to

create these pieces here and so it's

just a pipe that's been cut in half and

it will replace the rollers to again

eliminate any sort of potential movement

of the tubing while I'm trying to bend

it and I'll do the same on the other

side obviously I made two pieces so this

is the very first time that I'm going to

be attempting to bend this tube in a

pipe bender keep in mind this is

aluminum tube I don't know if that's

going to make a difference in comparison

to bending steel tube but we're going to

give it a shot and see how it turns out

I haven't taken any sort of previous

videos or tastes of this theme so we'll

really see first hand the first attempt

and if this thing actually ends up

bending or kinking this aluminum tube so

I have the tube in place I've marked off

the center of the bend where I want it

to be I've lined it up with the center

of this particular pipe die I'm here to

take my clamp piece here slide it into

place and we'll begin tightening it down

and clamping this tube into place I also

have a line on the top of the tube here

to give me some indication of where the

top is so that my next bend will line up

perfectly so now that I have everything

lined up and into place we're going to

attempt to make our first Bend on the

pipe bender turn into tube bender I'm

going to be trying to make a 120 to

prevent and that requires each side to

be bent down to about 30 degrees so

let's go ahead and see how this works




so once removed you'll see that there is

still some slight kinking on the inside

of this to which I'm a little bit

disappointed with but the only thing

that I'm hopeful about is that this is

aluminum tube and it's really thin

walled I'm wondering if maybe this will

turn out a little bit different if I

step up to a steel tube with a little

bit of a thicker wall and hopefully this

won't happen one of the other problems I

ran into was that with this die that I

created the inside diameter at some

points was really really tight and to

kind of got caught up in there and

you'll see some marking some witness

marks on the tube here from where it

kind of got stuck on this particular

piece here and so I think I'm just going

to take my grinder and just clean up the

edges a little bit kind of add a little

bit of a chamfer so that the tube can

slide in and out a lot easier without

getting stuck I was originally shooting

for such a tight fit that I think I went

a little bit overboard with this piece

starting to clean this up and we're

going to try again on the other side so

after several attempts of bending the

aluminum tube I consistently end up with

a small amount of crushing on the inside

of Bend the outside doesn't experience

any sort of kinking which is great but

the top of the bend also flattens out a

little bit and so at least for aluminum

tube I can't really say that I would use

this for anything structural for light

applications you know it might be

acceptable if you can tolerate the

slight crushing on the inside now I

don't know if this is just a function of

the wall thickness or the material so of

course we're going to have to try out

some different things

I went out and I picked up some steel

tubing of the same outer diameter so

this is again is one and a quarter inch

outer diameter it's steel tube and I'm

going to fix it into the clamp here

we're going to put it back in the pipe

bender and we're going to see if we can

get any better results with this steel

tubing all right so with the steel tube

clamps into place we can now proceed to

bend it and see if we get any sort of

crushing on the inside and see if it's a

function of material this is the same

wall thickness as the aluminum tube and

it's 1/8 inch thick let's go




okay so with the steel - things are

looking pretty promising there's a small

amount of evidence of crushing right in

the center of the bend if I didn't go to

the full 90 degrees that potentially

wouldn't even be there however of course

I do want to do full 90-degree bends

with this tool and so I need to make

some more minor adjustments to the clamp

I think I can get rid of this I'm going

to try one more piece of steel - right

after I make these modifications and

we'll see the results the last piece of

tubing all right so I've made the final

modification to this clamping piece and

what I've done is if you look very

closely inside here right in there

you'll see a little bit of a gap between

this top clamp piece and this die that

I've created now the reason for this is

that I've noticed in previous Bend that

the top of the bend will flatten out a

little bit as I bend it and I lost some

clamping force because the clamp was no

longer making contact with the tube

instead that clearance was taken up and

it was starting to contact that die and

I'm thinking this might be contributing

to some of the crushing on the inside

then it wasn't too bad last time but

like I said I'm going to try and get rid

of it completely so let's go ahead and

throw this in the pipe bender and see

what kind of results we get so one of

the change that's worth mentioning is

I'm going to go back to using these

rollers to support the tubes on the side

instead of these custom pieces that I've

made these guys seem to really grab on

the tube too much on the side and it

sort of pulls it in and doesn't allow

the tube to move so I'm thinking the

rollers will allow us to to kind of find

a tap in place and hopefully prevent

that crushing on the inside




so you're looking at the second attempt

and the third step and you'll notice on

the third step I bent this tube a few

degrees more than on my second try but

the good news is that there is slightly

less crushing on the inside so it looks

like the modifications I made are

working a little bit the second try if

you want to take a look at it again the

crushing is a little bit more pronounced

and like I said so the modification

schemes have made a little bit of a

difference but since there's still some

flattening and suppression these tubes

are not going to pass any sort of roll

cage inspection or anything of that

nature so you're I'm still limited to

you know light duty use for these bends

I'm definitely not going to be using

them for anything structural so this has

been my take on pipe bender turning tube

bender and the verdict seems to be that

if you want clean professional Bend

you're going to have to invest the money

in a proper tube bender but if you want

something quick and dirty you can come

up with something like this for not much

money and you can get some decent bends

or like you to use I'm probably going to

put this thing to use for some future

projects so definitely stay tuned for