The plot thickens- three roll bender build.
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  1. #1
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    Default The plot thickens- three roll bender build.

    I’m tickled- just got the plate in from the plasma shop.
    Some welding and bolt up work to go and this will be good to go.

    e9ace38b-1676-4cf4-9f8c-86a24ede0019.jpg

    Lucky find that old grinder base to bolt this to.
    Last edited by Trboatworks; 12-20-2019 at 08:18 PM.

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    Looking good!

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    Some photos of this coming along- still a bit more work to go before welding up...

    5124f4df-6d50-4053-a17e-9a290e14612b.jpg

    095d48a9-175a-4e18-9020-1e9570bde20b.jpg

    ce96e50e-d24d-4c0a-bc13-17c6b92ab276.jpg

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    What dies are you going to use?

    Sent from my SM-G973U using Tapatalk

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    I am turning the dies for the extrusions I have to roll.
    I made up bearing cores/carriers for the idlers and just press on a shell for each die while the drive wheel is a keyed slip fit.

    These are the idler cores from some 4140:

    aadc124a-e110-400b-9dcf-6bdb2782f422.jpg

    This is the idler set with flats for shell:

    ef873b5a-1a57-4c0f-9734-61cce4f71a7c.jpg

    The first set are just flats.
    These are 4” turned from some mystery plastic rod I had in shop- I think nylon.

    The idler axles are 1-1/8” 4140 and the drive axle is 1-5/8” scrap keel bolt.

    The drive axle not yet keyed for wheel or die.
    The drive dies will slip over axle and also have 4” OD.

    f1803898-6cb2-4e24-bc06-b81512afb93b.jpg

    I think the rig will have enough balls for the work I need it for.
    If it all works out I might power the unit and left room on the drive shaft for a pulley.

    It will take a few minutes to change out but this is an occasional use rig so that’s fine by me..

    I am kinda winging this and really have no ideal if it will work..
    This is the first extrusion I have to roll to a 12’ radius:

    8c57b4e5-ecb7-4e0d-aff2-341e1c8d8f3f.jpg

    That one is 3” x 1-1/4”
    Next up is 1-3/4” x 3/4” of the same shape but with two internal stiffeners.
    I intend to try both on flat die wheels.

    If this bender does the trick it will be a hoot- job well done.
    If not I will be wondering what the hell I have been doing for the last couple of days...
    Last edited by Trboatworks; 12-25-2019 at 02:55 PM.

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    Where did you get that hand wheel? It looks like a wheel off a race yacht.

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    It is- a 45’ wooden racer was cut up and this was her wheel.
    It seems the perfect size, is stout and already wrapped for grip.

    649a7f50-7dd2-4832-a3d5-a5dfc767def4.jpg

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    As it turns out the first stock I need to roll is a 2” x 1/8” architectural angle in 6063-T52.
    I need half hoops rolled the easy way to 1’-4” radius.
    Does it sound possible to roll that stock that tight?

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    Quote Originally Posted by Trboatworks View Post
    As it turns out the first stock I need to roll is a 2” x 1/8” architectural angle in 6063-T52.
    I need half hoops rolled the easy way to 1’-4” radius.
    Does it sound possible to roll that stock that tight?
    What do you mean by 2" x 1/8" angle? usually angle uses 3 numbers, leg, leg and thickness, like this: 2x2x1/8 or 2x1x1/8. You mention the easy way so one leg is shorter than the other...

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    Thanks- yes just equal leg: 2x2x1/8

    I was saying easy way for the leg in plane of bend on outside of loop.
    Given that I have never rolled any angle that is just my guess as to which way yields better..

    Edit- looked it up- this is called “leg out”.

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    If you have never rolled angle, you can be in for a big surprise. I have never rolled alum angle and without a good setup for angle, it can be real rough

    Sent from my SM-G960U using Tapatalk

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    Thanks- let’s see how this rolls...
    I should have this finished tomorrow and put to work next week.

    If I post bragging about some 1/4” flat rolled in a hoop the easy way you will know there is a problem...

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    Everything takes longer than I think.
    Tacked for welding up:

    246cdf03-fda2-4be2-bef6-587ca6014b5a.jpg

  20. #14
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    Quote Originally Posted by Trboatworks View Post
    Everything takes longer than I think.
    Story. Of. My. Life.

    Looks great!

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    Ok - it’s a wrap and it works:

    89322afe-86bd-4a9c-a784-efe80c055a09.jpg

    It rolls (no angle yet as I haven’t had a chance to make the dies) but, the oval rolls to the radius I need and an obligatory hoop...:

    34d11425-5057-4c53-a0ab-63e2b10b12db.jpg

    This whole thread sorta has a HSM feel to it already so I have nothing to lose..::

    I had thrown out the shaper which I never used so had to do the lathe trick to cut the inside keyway for the drive wheel which I had never done- it works

    d444054c-91d0-4b4f-8d37-971e61af493f.jpg

    402bf284-b8f9-4771-9da5-7f22bb3b3eae.jpg

    One oversight- In the fullness of time I am going to replace the top axle and carry it further out the back side to have a set of open dies.
    I had wanted full support for the primary rollers so I could really lay into them for heavy work but seeing this now a open set would be a snap for small stock in closed loops etc.

    Shoot- now that I supposedly know how to weld I can weld on a stub axle and save me the work of turning the whole thing again.

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