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BP0368 Bender (construction information)
by Pmusics
This construction information should you give more an idea to build your own bender, than give you some exact measurements. The drawings are slightly different to the photographs, since it was already re-designed and I just left out unnecessary cuts in order to save time (and money). Way of working:
Find a useful double-T profile and cut about 400mm away from it
Separate the 2 sides if you like a smaller bender than the original T-profile has.
Cut out a center part wide enough to get access into the bender. This will not affect the material entered into the bender, if the center of the support-wheels is higher than the center line (horizontal) of the T-profile (!!)
I did choose about 65mm wide (so the support wheels are not stressed too much (as longer they are as less stable).
Modified drawing (not as in photograph) to cut out the side piece easier.
All about the dimensions. First, make sure that the center of the support wheels is higher than the horizontal center line of the T-profile. This will allow the material to go through the bender without interfering with the horizontal plate of the t-profile.
The support wheels I used are 30mm in diameter, the cartan wheel is 44.5mm in diameter (measured over the teeth). Since the cartan piece was ground at the shaft to its “solid diameter” please keep in mind to cut the vertical piece according to its shaft diameter (and not the diameter measured on the teeth!)
You should allow the cartan wheel to go complete underneath the horizontal center line of the support rollers (even if never used, it will give you “enough play for adjusting the position of cartan wheel in regard of the desired bend-radius
Position of two little fixations of support rollers (horizontal) and position of steel-tube (vertical). Allow a little play for the support roller’s axe and allow a little play in the tube for the thread bolt to move up and down
Basic drawing of support wheel diameter 30mm and its hardened steel bolts.
Basic drawing of cartan wheel. I ground away the teeth over about 50mm on both side. Than took a sandpaper and ground the shaft “round”. If you have a drill bank at home you can use this one to take away the teeth of the wheel.
Side view of bender. The tubes are not used anymore (left/right side) and the “windows” are not used, cut them out as shown on drawing. Bottom plate soldered to give stability to bender.
Feel free to determine the “wideness” of your bender yourself, but keep in mind that as wider the bender will be, as longer the support rollers are and as less stable they got.
Here again, I used a 44.5 mm diameter cartan, did grind away the teeth to both ends of the shaft and cut then out the vertical area to allow the shaft a little play but still make sure the inner diameter (of teeth) is bigger than the area cut out. This will hold the cartan wheel in the center position. I used some washers to center the support wheels.
Here you see the horizontal movement of cartan done by thread bolt. This must probably later be redesigned because after bending the circle the bolt must be completely loose in order to lift out the cartan and evacuate the bended circle. Please take care that the bolts will go below the bottom line of the bender.
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