Cadflat Tube Bender Project.

[Oddbod]

Sorry folks, I've been distracted TCB once more.
I needed to move my recently purchased 2nd hand treadle sheet metal guillotine.
It is one heavy sucker and since I had already found some suitable double castor wheels from FB Market Place for cheap I figured it was about time I finished this job.

[Oddbod]

Unfortunately, I've have been struck with a further distraction for now, but I'm almost done with it.
A steel cutting bandsaw I purchased a while back, which I thought would be OK and ready for use turned out not to be.
It had sat in an open farm shed for 5 years and got infested inside by rats.
An intital clean out saw 7 dead rat carcasses as well as much chewed up paper, leaves and miscellaneous crap etc.
I assume the farmer had laid poison and they had taken it back into the nest, where they died.
It stank to high heaven and I ended up burning incense inside the wheel house inclosures to help neutralise the stench.

Not having any experience with large bandsaws, I figured that I was now good to go...
Eventually, I got power to it and it ran OK.

Outside appearances can be deceiving.
However, I quickly discovered that I had no adjustments that would work.
It did not like cutting in a straight line and all threads etc had been corroded by rats pee and time.

So now, I have just completed a rebuild of the top wheel adjuster mechanism, which had to be removed with great difficulty and soaked in diesel for a number of days, yet still required several applications of heat and pressing to free it up.
Fortunately, no damage was done and I have now gotten this unit re-installed and adjusting.

A similar effort was required to free up the lower wheel house which contained the speed adjustments and belt tensioning etc.
That is now behind me, but I find that the saw does not cut straight and the drop down blade guide needed attention, including freeing it up as it was also frozen.
I've come to the conclusion that rat pee is way stronger than Loctite...

In the process of unfreezing the blade guide, I now realise that there are two blade guides and upper unit which is visible and easily accessible, but also a lower guide hidden under the table and hence more seized and frozen bolts and items to remove.

I can say that I have now been well introduced to the inner workings of my bandsaw which I guess is a plus.
Looking at YouTube videos and talking to some guys on a Forum I joined for help, I've decided that the old style fixed metal side blade guides and the rear blade roller bearing is not the industry standard any more, so I've decided to try and modify both the upper and lower guide units incorporating roller bearing side blade guides as well and as re-orientated rear roller bearing guide.

So far I have not achieved all that much progress in this regard as most of my time has been spent contemplating and acquiring suitable sized bearings etc.
Using roller bearing guides seems to be a means to achieve better blade control and reduce friction/heat on the blade which I am told heat is a blade destroyer and blade life reducer, which I guess is obvious.

I dont want to distract too much from my project build but found that I needed to deal with the bandsaw issues and figured others may find some of what I have said as useful.

With regards to my bender project, my next post should included the results of my 1st 1"NB tube bend.
So stay posted...

[Oddbod]

As promised I am the bearer of good news.
While my bandsaw stuff continues to consume my time, I took time out to see if I could finally set my partially finished bender up to bend a length of what I know as 1" NB tube which has a 1/8" wall and O/D is about 1 1/4".

Since I had previously set up my 1 1/4" form that I scored way back when which will be able to handle this diameter tube, I mocked up a guide just using 2" x 2" angle iron and only tacked it all together for this test bend.
For my completed machine I plan to use a roller style guide and not a slide style.

I have been wanting to do this test for some time in the hope that all will be well and it will provide me with the motivation I need to keep pushing ahead.

Anyway, the bend was made and it went well and everything held together.
Upon review of the bend, the elongation was not all that noticeable thru the curve, but I appears that I may need to grind the sharp start point of the form as it it is marking the tube slightly.
I had a friend inspect the two bends and he was impressed.

So check out the pic's and merry christmas to you all.

Russ.

[Esteban]

Congratulations Russ! The curvature looks very neat.

It’s been very interesting to follow the progress. I’m glad that the outcome is as you envisioned.

Merry Christmas!


Esteban

[RiverPatrol]

Congratulations! Very impressive. Job well done.

[Oddbod]

Next step is to attempt to make a form that will accept 2" OD tube as that is the other size I need to target and hope my machine is capable of bending it.

Since I dont have a form for that size I will need to source some metal stock and head off into uncharted waters.
My main concern is having a piece of stock large enough to fall within the range that is a suitable radius for 2" tube bending, but at the same time fit in my or my buddy's lathe and chuck.

I was aware of a potential source at my local laser cutting and metal suppliers yard.
They carry and cut steel plate in excess of 6" thick.
Boy you want to see slabs of steel that thick, it is scary and no second chances it it dropped.

It seems that they cut out holes in orders, the waste cut out of a hole is called a drop out.
I targeted 3" thick drop outs at approx 8" diameter, still a substantial piece of steel weighing in at about 45 lbs.
I scoured a drop out and then had to carry it about 400 yards back to be weighed and paid for in the Office.
You dont realise how heavy it is during the first few steps but soon discover it is no fun.
Usually the drop outs are left under the laser cutting table until a scheduled clean out is done using a small bobcat style machine.

Anyway I get this darn thing home and determine it ain't gonna fit my chuck and will be tight for bed clearance as well.
I check with my buddy and he too does not have a chuck capable of holding this drop out but his bed clearance is better.
We figure that possibly a hole drilled thru the approx center of the drop out and a shaft thru the hole and locked in a chuck at one end and the other end fixed into the live center could be an option.

We drilled a 15/16" hole and I machine down a short length of round bar that I find, that I machine down to hole size with the intention of pressing it in the hole.
It turns out that this configuration will just fit into my small lathe reluctantly and I still wondering if it is capable of doing the job.

Fingers crossed for now...
And that my friends is where I am upto right now.

[RiverPatrol]

That is one monstrous piece of steel right there.

[Oddbod]

Yes, it is a great start, but I must proceed cautiously.
The weight is equal to that of a packed suitcase you would take on a holiday 20kgs.
We are not talking carry-on, this a full luggage.

It only just fits into my lathe, but tool cutter adjustment is serverely limited and could end up being a major issue as I proceed.
I still have no idea how the hell I am going to make and setup my curved cutting tool to create the form shape for 2" diamter tube.
I decided to take 1 step at a time and am quite willing to accept defeat if I hit a brick wall.

[Oddbod]

Still taking small steps and confidence building since it is all new to me working in the big pond for a change.
I am using slow gears and pressed the shaft into my drop out and it was a really sweet fit.

I've set it up and other than the rough laser cut, I was pretty close to center and have now gotten a decent machined surface to the perimeter. That laser start cut was a bit annoying to start with but now is fine.
Next, I will face the side opposite to the chuck and then contemplate the mounting and making of my concave radius cutter gizmo...

Its been a little too hot for the shop over Christmas with 2 days straight of around 44 degrees C where I am and still more heat to come...

Stay tuned.

[Oddbod]

I've scrouged up some scrap metal from my stash and have started making the parts for my radius cutter gizmo.
Pictured is what I have to date.
I am running with what I have, so no ball bearing, just an acorn nut will have to suffice...

It has also been quite hot where I reside, we are talking temps in the 40C degrees range.