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View Full Version : Been working on a new tool for my shop...



Cebby
04-26-2005, 10:10 AM
Not there yet, but a big leap forward recently:

http://rigs.corequipment.com/Cebby/Shoptools/Bender/Hydro%20Frame%20005%20(Medium).jpg

http://rigs.corequipment.com/Cebby/Shoptools/Bender/Hydro%20Frame%20004%20(Medium).jpg

http://rigs.corequipment.com/Cebby/Shoptools/Bender/Hydro%20Frame%20003%20(Medium).jpg

The hardest part of this process (besides finding the time lately :roll: ) was drilling some of the holes. I have a drill press and sharp bits, but damn that steel is thick (and heavy!).

Here's the short of it so far:

- Bottom is 6" Ship Channel cut to 42" long.

- Top plate is 3/8" plate also cut to 42", notched to clear the bolt on the end of the ram.

- Stationary end of the ram has two pieces of ship channel welded together in an "H" and welded to the top of the ship channel. This is the same height as the assembled stationary part of the bender arms. (around 5 1/4" IIRC)

- Top plate will be welded to the "H" and plated/welded around the stationary end of the bender arms.

- Ram is attached with 1" Bolts. Bolt is sleeved at stationary end (sleeves welded to channel and plate)

The stand is next - it will have die storage, of course the pump, and a shelf for other stuff.

I have 1", 1.25", 1.5", 1.75" and 2" dies for it. :smt080

OverkillZJ
04-26-2005, 10:55 AM
I smell some tube bending coming up.

RedneckYJ95
04-26-2005, 02:27 PM
What the hell is that thing? 8O

Cebby
04-26-2005, 04:02 PM
What the hell is that thing? 8O

Flux capacitor.

j/k - it's a hydro tube bender

DMG
04-26-2005, 07:09 PM
Sweet! When do I get to play with it? DMG

Cebby
04-26-2005, 08:43 PM
It will probably be ready for bending at the end of next week or so. I think I need one or two hydraulic fittings to complete it (aside from finishing the stand, etc.

What color should I paint it?

Cebby
05-20-2005, 08:33 AM
A few time constraints have dragged this thing out longer...

But, now she's got legs...

http://rigs.corequipment.com/Cebby/Shoptools/Bender/Legs001%20(Medium).jpg

http://rigs.corequipment.com/Cebby/Shoptools/Bender/Legs003%20(Medium).jpg

http://rigs.corequipment.com/Cebby/Shoptools/Bender/Legs007%20(Medium).jpg

I was going to make a shelf underneath the pump shelf, but I like the idea of being able to stand in close to this thing if need be. I've decided to make the die storage kind of hang down from the shelf where I'll have pins welded to it to slip in the dies and followers. This will also keep the weight nice and low to balance when I have a heavy stick I'm bending.

Cebby
05-20-2005, 08:36 AM
Here's progress from last night:

http://rigs.corequipment.com/Cebby/Shoptools/Bender/Progress519%20001%20(Medium).jpg

http://rigs.corequipment.com/Cebby/Shoptools/Bender/Progress519%20003%20(Medium).jpg

http://rigs.corequipment.com/Cebby/Shoptools/Bender/Progress519%20005%20(Medium).jpg

http://rigs.corequipment.com/Cebby/Shoptools/Bender/Progress519%20009%20(Medium).jpg

http://rigs.corequipment.com/Cebby/Shoptools/Bender/Progress519%20010%20(Medium).jpg

Bill
05-20-2005, 03:05 PM
Lookin good! :wink:

OverkillZJ
05-20-2005, 03:50 PM
sweeeeeeeeeeeeeeeet

Cebby
05-29-2005, 12:31 AM
Getting closer...

Here's a few updates:

Prior to welding the top plate on:
http://rigs.corequipment.com/Cebby/Shoptools/Bender/Progress521%20001%20(Medium).jpg

All welded with the top plate on.
http://rigs.corequipment.com/Cebby/Shoptools/Bender/Progress521%20005%20(Medium).jpg

Just need to position the valve and mount everything up...
http://rigs.corequipment.com/Cebby/Shoptools/Bender/Progress521%20006%20(Medium).jpg

Painted up:
http://rigs.corequipment.com/Cebby/Shoptools/Bender/ol-twisty-blue%20004%20(Medium).jpg

Reassembled after paint.
http://rigs.corequipment.com/Cebby/Shoptools/Bender/528-progress%20002%20(Medium).jpg

I unplugged the ram and cycled it through the range of motion. It appears that I'll get between 110 and 120 degrees in 1 shot. I'll get a good measurement when everything is hooked up and running under it's own power.
http://rigs.corequipment.com/Cebby/Shoptools/Bender/528-progress%20004%20(Medium).jpg

http://rigs.corequipment.com/Cebby/Shoptools/Bender/528-progress%20008%20(Medium).jpg

I figured out that one or two of the hoses I have are too short. I want to have my valve near the die and the power unit as far toward the opposite end as possible for counterbalance when bending heavy stuff. In fairness to Jay, he said the sizes may need to be adjusted - he was right.

The remaining to do list is getting shorter:
-Drill and tap the top plate to mount the valve
-Exchange the hoses for correct length
-Get a couple of small fittings to connect the hoses
-Wire up the motor/switch
-Fill the fluids

then

-Bend some tube!!

MF Steve!
05-29-2005, 12:48 AM
dude...you're one bad mofo. nice welds...finally someone w/ nice welds aside from me. whats the diameter capacity on that beast?

Cebby
05-29-2005, 01:21 AM
The biggest die I have is 2". I think this is the biggest they make.

I also have 1", 1.25", 1.5", and 1.75" :D

I'm thinking about adding a square tube die to the mix, but need to decide which size.

MF Steve!
05-29-2005, 01:40 AM
like as in biggest made for your particular bender, or biggest they make in general? cuz i know you can get bigger ones...


The biggest die I have is 2". I think this is the biggest they make.

I also have 1", 1.25", 1.5", and 1.75" :D

I'm thinking about adding a square tube die to the mix, but need to decide which size.

Cebby
05-29-2005, 01:48 AM
Biggest made to fit the JD2 Bender Arms.

MF Steve!
05-29-2005, 01:57 AM
i see...to bad you cant get a 2 1/2" and a 3". it'd be sweet to be able to do custom exhaust work...

Cebby
07-03-2005, 10:55 AM
Here's some pics of it pretty much finalized:

Valve mounted up top. I drilled and tapped the top plate 5/16-18 and used socket head bolts. I slipped a rubber washed under each mounting point also. Did a similar mount for the pump.

http://rigs.corequipment.com/Cebby/Shoptools/Bender/Hoses-Valve%20done%20002%20(Medium).jpg

http://rigs.corequipment.com/Cebby/Shoptools/Bender/Hoses-Valve%20done%20003%20(Medium).jpg

I had to "customize" a wrench to tighten the fittings on the pump.

http://rigs.corequipment.com/Cebby/Shoptools/Bender/Hoses-Valve%20done%20006%20(Medium).jpg

Here's the valve with all the hoses hooked up:

http://rigs.corequipment.com/Cebby/Shoptools/Bender/Hoses-Valve%20done%20007%20(Medium).jpg

Here's a couple overall shots:

http://rigs.corequipment.com/Cebby/Shoptools/Bender/Hoses-Valve%20done%20008%20(Medium).jpg

http://rigs.corequipment.com/Cebby/Shoptools/Bender/Hoses-Valve%20done%20010%20(Medium).jpg

Bill
07-03-2005, 01:07 PM
Looking good!!!

But did nobody else see the sign?
http://rigs.corequipment.com/Cebby/Shoptools/Bender/Legs001%20(Medium).jpg

Cebby
07-03-2005, 07:38 PM
But did nobody else see the sign?


:wink:

OverkillZJ
07-03-2005, 10:01 PM
must....make...exocage....


:D :lol:

Cebby
07-03-2005, 11:32 PM
After a slight delay due to some wiring confusion (cryptic schematic on pump), it is up and running.

Right click and "save as"

320 x 240 (3mb) (http://rigs.corequipment.com/Cebby/Shoptools/Bender/Cebby's%20Hydro%20Bender%20320x240.wmv)

640 x 480 (17mb) (http://rigs.corequipment.com/Cebby/Shoptools/Bender/Cebby's%20Hydro%20Bender%20640x480.wmv)

OverkillZJ
07-03-2005, 11:41 PM
I absolutely positively need to build one, especially all bent unibody considered...

I just drooled over that video so much that I'm sure everyone else in the room thought I was watching Pr0n.

Cebby
09-15-2005, 07:50 AM
I'm making a modification to the bender. Due to how difficult to it is to remove the center die pin, I've decided to drill out the die pivot hole in the arms (both the stationary and movable arms) for a 1 1/4" bushing. This should eliminate some of the binding I'm experiencing (when trying to remove the pin). I don't have a bit this big, so I'm having a buddy (who has a metal shop) enlarge the holes for me.

Here's the bushings:
http://rigs.corequipment.com/Cebby/Shoptools/Bender/Bushings%20(Medium).jpg

McMaster Carr
P/N 7815K56 (http://www.mcmaster.com/ctlg/DisplCtlgPage.asp?reqtyp=catalog&CtlgPgNbr=1007&sesnextrep=526323327756947&CtlgEdition=111&k1=7815K56&t1=PN&ScreenWidth=1920&McMMainWidth=1713#scroll)
Alloy 932(SAE 660)BRNZ Flanged-Sleeve Bearing, For 1" Shaft Diameter, 1-1/4" Od, 1" Length

bigblackjeep95
09-15-2005, 08:44 AM
dude that thing is just 2 sweet man!! excellent fab and welding man!!

Cebby
09-16-2005, 02:46 PM
Here's the bushing installed. I need to run my 1" drill bit down through the hole in the bushing. Seems to be a hair too tight to get the pin in.

http://rigs.corequipment.com/Cebby/Shoptools/Bender/Bushings%20001%20(Medium).jpg

Cebby
09-23-2005, 02:36 AM
Finally got my writeup done...

Cebby's JD2 Model 3 Hydro Conversion (http://reference.toolandfab.com/writeups/hydrobender_webpage/index.htm)

Cebby
09-23-2005, 09:49 PM
Added a downloadable PDF version of the writeup and PDF of just the Parts List.

OverkillZJ
09-24-2005, 09:46 AM
Added a downloadable PDF version of the writeup and PDF of just the Parts List.

You're my hero.