Bending the 2" radius rear corners

Post by **chetcpo** » November 17, 2007, 1:01 pm

I built a little bending jig to do the top corners of the rear, but the bottom corners and their super tight 2" radius bends have confounded me for a while. I finally got them done, here's how I did it.
I drew out a template on cardboard and then cut slots into the tube about 2/3 of the way through, every 1/4" or so on the area of the tube I wanted to bend. I then bent it to match the template. (actually I made it a slightly larger radius, expecting some weld shrinkage on the inside of the bend. I then welded up the cuts I had made and then ground it smooth again. I then had to tweak the bends in a vise slightly to adjust them after it cooled. It really wasn't as big a job as it appears. It took me about an hour to do both corners.

KB58 · Post by **KB58** » November 17, 2007, 5:35 pm

Sometimes a lot of tweaking. Each weld contracts quite a bit, add them all up and the 90 degrees you were hoping for can end up being about 75...

mookie · Post by **mookie** » November 17, 2007, 7:46 pm

The finished product looks pretty amazing. I've read of people doing this before. My Dad did it with wood all the time. Good job though, and you didn't have to buy or build an expensive bender to do it!

Post by **chetcpo** » November 17, 2007, 10:32 pm

Thanks Mookie.

Blackbird · Post by **Blackbird** » November 17, 2007, 11:14 pm

Chet -

Looks great!

Are you doing a different radius corners on the top and the bottom?
From looking at pics I personally prefer a similar radius... question of taste, I guess

.

Moti

Post by **chetcpo** » November 17, 2007, 11:18 pm

Blackbird wrote:Chet -

Looks great!

Are you doing a different radius corners on the top and the bottom?
From looking at pics I pernally prefer a similar radius... question of taste, I guess .

Moti

Thanks Moti, yeah I'm using the "book" Mcsorley dimensions for the rear. IIRC the upper bends are on a 7" radius and the lower bends are on the 2" radius. I've seen several people just bend a flat piece of stock for these lower corners since it is easier but since I will be forming aluminum around these corners I wanted to use the round tubing. I plan on using a mallet to hammer the aluminum around the bottom tube for a nice seamless look.

Mandurath · Post by **Mandurath** » November 18, 2007, 1:33 am

Did you do that after seeing it done with wood? Never even though about it working with steel. Damn smart!

Post by **chetcpo** » November 18, 2007, 11:54 am

Mandurath wrote:Did you do that after seeing it done with wood? Never even though about it working with steel. Damn smart!

Yessir, that was my inspiration after kinking about a half dozen tubes trying various other methods.

Mandurath · Post by **Mandurath** » November 18, 2007, 2:11 pm

Heheh after building my share of decks for friends and myself, this is one of those times where you smack yourself in the head with the answer being right there.

zetec7 · Post by **zetec7** » November 18, 2007, 11:25 pm

This technique works just as well with square tube, as well. I did this to build a support bar (kind of a really wide, rounded "V" shape) across the underside of my driveshaft tunnel. I wanted to use 1" square for this, as it was easier to make the ends fit the other square tubes on either side of the tunnel. Once it's cut, welded & ground down, you can't tell it didn't come that way.

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Bending the 2" radius rear corners

Bending the 2" radius rear corners

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