Making a pipe bender with your own hands: design options and features of finished products

The construction of greenhouses and sheds, the laying of utilities - all this requires a bent metal profile. But buying pipes bent to order is expensive, and purchasing a ready-made pipe bender is also not a cheap pleasure. So modern craftsmen use devices and self-made mechanisms to create metal arcs of the required radius.

In this article we will consider the following questions:

• Types of homemade pipe benders and their features.
• The design of the simplest device for bending square pipes.
• Design of a three-roll machine for bending round and square pipes.
• Technology for bending pipes using a three-roll homemade pipe bender.

Manufacturing a pipe jack bender

A pipe jack bender is the most basic tool for deforming metal profiles and pipes, which you can build yourself.
To make it you will need the following products:

• car jack;
• two channels 100 mm wide and 60 cm long;
• four corners with sides 50 mm and length 40 cm;
• base-bed;
• two hourglass-shaped rollers with through central holes;
• 2 bolts for fastening the rollers;
• semicircular attachment for a jack with an internal recess.

If the procurement of raw materials and the assembly process seem to you to be unnecessarily labor-intensive, then it is better to purchase a hydraulic pipe bender ready-made. Our recommended article will introduce you to the rules for choosing equipment.

To make a pipe jack bender you need:

1. Weld four corners in a vertical position to the frame.
2. In the channels, from the center to the edge, drill holes in both directions for the bolts that will hold the rollers.
3. Place a channel on each two corners and weld it. Both channels should be turned towards each other with their bases, and the distance between them should be equal to the length of the rollers.
4. Insert rollers between the channels in symmetrical places and secure them with bolts.
5. Place a semicircular attachment on the jack screw and place the hydraulic tool in the center of the frame between the channels.

After assembling the structure, you can place the pipe at the bottom of the rollers and press it in the center with a semicircular nozzle using a jack.

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Rusty parts of a pipe jack bender

Installation of rollers between channels

Putting the attachment on the jack

How does a pipe jack bender work?

The disadvantage of this device is that it is static, because it will not be possible to rotate the entire length of the profile through a pipe bender.

The advantages of a pipe jack bender include low cost, simplicity of design and no need for hard physical labor.

Those who want to make a machine for working with profile pipes will find a lot of useful information in the following article, the contents of which we recommend that you familiarize yourself with.

A simple device for bending metal pipes

The design of a homemade pipe bender depends on the volume and complexity of the work that is planned to be performed with its help. If the device is needed for one-time use (for example, for building a home greenhouse), then there is no need to create a complex three-roll mechanism with hydraulic adjustment of the bend radius.

belor44 FORUMHOUSE user

We urgently need to install a greenhouse. I want an arched one, but neither one based on metals nor my friends have a pipe bender. Build a pipe bender on shafts and rollers? There is neither time nor need for this. I think that a device for manual bending is suitable for one construction.

Yes, indeed, the simpler the pipe bender, the less hassle there is in its manufacture. The main thing is to correctly determine the dimensions of the device, which will directly depend on the bending radius.

We present to your attention a device made by the user moning. It is designed to work exclusively with thin-walled pipes, because bending pipes by hand is hard physical labor.

Moning User FORUMHOUSE

I made this thing for a 30*30 square pipe. The radius that was obtained was approximately 1 meter. You can weld something like spacers or legs on the sides of the device so that it doesn’t throw from side to side when you press on the pipe. Regarding the jumpers at the bottom of the pipe bender: first, the pipe is placed under the top jumper (for the initial bend), then the pipe is placed under the next jumper (for further advancement).

Consistent bending is necessary so that if there is a sharp bend, the pipe does not break.

Calculating the dimensions of the device is very simple: to do this, it is enough to know the bending radius that needs to be obtained on the finished part. The strip (40 mm wide), which serves as a mandrel for the workpiece to be bent, initially has a curvature that provides a given bending radius (R).

Taking into account the presence of elastic deformations, the radius of the mandrel should be slightly smaller than the required bending radius of the workpiece.

According to the author of the invention, the radius of the workpiece is, although not significantly, larger than the radius of the mandrel itself.

Knowing how to use welding, a grinder and auxiliary tools, this device can be made in less than 1 day.

Each metal pipe has its own elastic limit, therefore, the bending radius cannot be reduced below certain values. Permissible minimum radii can be taken from the corresponding tables.

We present an example of a table of permissible radii for round pipes.
Minimum bending radii of pipes in a cold state

Pipe bender and components for its manufacture

Considering the topic of the article, it is not difficult to guess that further we will talk about the independent production of a pipe bender used in relation to profile products. You can, of course, purchase such a device at a specialized hardware store. Typically, models produced for sale differ in the principle of operation, and may also differ in the way electrical wiring is connected to them, if we are talking about automatic machines with a gearbox.

The following units are distinguished:

• certain requirements for experience with similar installations;
• high cost.

If any of the conditions do not suit the novice worker, then the best way to deal with the problem that has arisen will be to use a detailed diagram, according to which you can create a pipe bender for a professional pipe with your own hands, in order to achieve minimum costs and maximum quality.

The most popular and easiest to manufacture are frontal pipe benders, consisting of the following elements:

• three metal rollers/shafts;
• drive chain;
• axis of rotation;
• a mechanism that creates traction to set the entire structure in motion;
• metal profiles to create the frame of the unit.

It is better not to skimp on the elements of a homemade pipe bender, unless of course we are talking about creating a disposable device that can break after the first session of work.

A rolling pipe bender works using a certain technology, without knowledge of which it will be quite difficult to make the correct bend without damaging the pipe. Typically, the pipe bending process is carried out through flaring and rolling procedures, which minimize the risk of deformation and complete fracture of the pipe.

Visually, the process looks quite simple: a profile pipe is inserted into the device between the rolling rollers, and then the handle is turned. This design easily forms bends at a given angle and taking into account other parameters.

The simplest homemade machine consists of the following functional elements:

• ordinary jack;
• a set of metal profiles and a shelf for forming a frame;
• springs with increased strength;
• 3 rollers;
• drive chain and various small spare parts, fasteners.

Templates and springs

If pipe bending will not be permanent, but most likely one-time, for example, if it is necessary to build a greenhouse in a country house or a carport, then it is not necessary to build a complex product. A round or profile pipe can be easily bent with minimal effort without the use of special tools.

Existing manual bending methods allow you to change the configuration and direction of pipes with a decent radius and minimal risk of damage to the internal surface. If the task is to bend a thick-walled pipe, then a winch or jack can serve as a traction device. However, if it is necessary to work with pipes with a diameter of up to 40 millimeters, it is enough to apply a little physical effort and muscle strength.

In any case, creating a homemade pipe bender is a completely doable and relatively simple task. Large financial costs are completely absent, if you do not take into account the need to purchase a jack. However, even here the price of a homemade tool is much lower than in the case of purchased solutions.

How to make a hydraulic pipe bender

Using the device described above, it will not be possible to bend profile pipes at an angle of more than 50-60 degrees. For such purposes, you will need a hydraulic pipe bender that has a different design and operating principle.

Making such a device yourself is quite simple. The entire process of its assembly consists of the following steps:

1. 4 corners 300-350 mm long are welded to a metal plate with dimensions of two sides of 300×300 mm and a thickness of 8-10 mm.
2. Two channels with pre-drilled holes for support rollers are welded to the corners. The holes on the channels are not located in one line, but in a ladder - this allows you to change the bending angles of the pipe.
3. A jack is installed on the slab.
4. A “shoe” is put on the jack rod - an attachment for bending a pipe in the shape of a semicircle.
5. The support rollers are made of durable steel and have through holes in the center - they are designed for axles.

After this, the shoe, by lifting it with the jack rod, is installed at such a distance from the plane of the support rollers that the profile can be inserted there. Next, by lifting the shoe with the jack rod, the profile is bent at the required angle.

When making a similar pipe bender for a profile pipe with your own hands, it is best to purchase a “shoe” and shafts rather than make them yourself.

Types of machines

According to operating requirements, a distinction is made between fixed (stationary) and manual machines. Stationary structures are used to a greater extent in factories. A hand-made device made with your own hands is more suitable for performing work in a domestic environment.

Depending on the drive, there are several types of pipe bending devices:

• Hydraulic (a hydraulic jack is used). They are stationary and manual. Bends pipes up to 3 inches in diameter. Such machines are used in special industries and can carry out an impressive amount of work.
• Mechanical. The pressure is generated manually using the main screw or lever.
• Electrical. Bending occurs due to an electric motor), suitable for bending any pipes - both thin and thick walls. Thanks to electronics, precise calculations of the bend angle are made. Such pipes have no deformations.
• Electrohydraulic. The hydraulic cylinder is powered by an electric motor.

It is possible to bend a pipe in different ways.

In this regard, pipe benders are divided into:

• Segmental. They are equipped with a special device that simultaneously pulls and bends the workpiece at the desired angle around the segment.
• Crossbow type machine. It is equipped with a special mechanism consisting of a bending component.

• Spring devices. Supplied with springs. On such machines it is possible to process metal-plastic parts.
• Turf. It consists of a guide, which is placed inside the pipe before starting work. Such an element with a mandrel protects the part from deformation and flattening. This machine is used in the production of automobile pipes and for bending aluminum pipes.
• Lint-free. Bending is accomplished by winding the part onto a bending roller.

Depending on the length of the workpiece that needs to be bent, two types of devices are used:

• lever machines;
• rental devices.

Lever type devices are considered the most common in use. Turf and crossbow pipe benders are also commercially available. The operating principle of such machines consists of two guide rollers and a pressure template (mandrel). This mechanism makes it possible to cold process round metal pipes in small areas. Due to its small size, the crossbow pipe bender is considered a more common device among professional installers of technical communications. The device got its name due to the fact that the design is similar to a crossbow.

To produce a significant number of monotype parts with a small bending radius, it is possible to use a snail pipe bender. This device consists of two pulleys (wheels) of different diameters, fixed on shafts. Having secured one end of the pipe to the wheel, apply pressure to the workpiece with a roller of the smallest diameter (the main wheel), while at the same time rolling the roller over the area of ​​the part being processed. Because of this, the pipe bends along the surface of the large pulley, taking on its shape. The only disadvantage of this method is the impossibility of extracting curves of a larger radius.

Do-it-yourself rolling (bending) machines, in which it is possible to adjust the angle of deformation of a metal pipe, are considered practical and universal in operation. The simplest system of a rolling machine consists of a base and a drive shaft fixed on it, located at a certain distance from each other. The pressure on the pipe is exerted by a movable roller, and it is pulled through the rotation of the main shafts. When creating small radius bends, you will need to make 50-100 runs. To avoid deformation, the product should be rolled at the same speed. It will be difficult to assemble the rolling mechanism yourself at home, since turning and welding work will be required.

Types of pipe bending mechanisms

Devices that allow you to bend a steel pipe to a certain radius are divided according to the following characteristics:

• Mobility. Pipe benders can be stationary or portable.
• Type of drive. Depending on this feature, manual, electric, hydraulic and electro-hydraulic devices are distinguished.
• Method of influence. The tubular product is bent under the influence of rolling, winding, rolling and rod.

Before you make a pipe bender at home, you need to understand how the device affects the workpiece and become familiar with each process separately.

Run-in

This method involves performing the following actions: one end of the tubular product is pressed against a stationary template and the pipe is rolled around it using pressure rollers.

Winding

This type of device has a movable template. A pipe is directly wound onto it, which passes between the template and a special stop located at the beginning of the bend.

Crossbow type pipe bender

This device is equipped with two fixed rollers and a template mounted on a movable rod. When the rod presses in the middle of a certain section, the pipe bends.

Rolling

The design is made on the basis of two support rollers and one central roller. This three-roller mechanism helps to obtain the required radius when bending as a result of pressing the central roller on the pipe, the position of which determines the bending radius. This makes it possible to call this type of pipe bender universal, since all other types bend the pipe according to a specific pattern.

A pipe bender operating on the winding principle is quite difficult to make at home, so industrial enterprises produce such mechanisms. When using a crossbow pipe bender, it is worth remembering that the impact of the rod on the pipe product can cause the material to rupture. Consequently, these mechanisms are not suitable for bending products with thinner walls. The rolling device has no significant disadvantages; it is used in the factory production of bends.

The design of a machine for bending home-made tubular products can be varied. Select the desired device according to the required bending radius

In addition, it is worth studying the recommendations for choosing a device, and also taking into account the main parameters of the pipes used: diametrical cross-section and wall thickness.

How to bend a profile pipe without a machine

There are two ways to make an arc from a profile pipe without a profile bender - using welding and a template. Let's start with welding.

Get an arc by welding

The profile pipe is cut with a grinder on one side. They are made every 15-30 cm, depending on the required radius, cross-section and wall thickness. The cuts should not touch one side - the one that will be on the outside.

Result of bending by welding

The spare part prepared in this way is bent, giving the desired bend. For reliability, the edges of the arc can be fixed by welding a rod to them. Then welding is carried out along all the cuts, welding them. And the last stage is grinding the weld spots and treating them with anti-corrosion compounds.

Using a template

Thin-walled profiled pipes can be bent by hand using templates. If you need a special shape, it can be cut out of a piece of thick plywood or chipboard and secured to the table using clamps. On the workbench where we will bend the pipes, make about 8-10 holes. The template is placed near these holes.

The process of obtaining an arc from a profile pipe using a template

The holes are repeated at one end of the pipe; with their help, the pipe is attached to the workbench. Now the free end of the pipe begins to be pulled smoothly, forming a bend that follows the shape. You need to pull smoothly, without jerking.

The template can also be made on the ground. Pipes-pegs are driven into the ground (at least half a meter deep). They form the required arc. For emphasis, two additional stakes are driven in, which are located to the side of the arc. The distance you need to step aside is slightly greater than the width of the pipe.

Pattern on the ground

Having inserted the pipe, it is pulled towards the arc. Great efforts are required, the work is hard. This can only be achieved with a thin-walled, seamless pipe. The suture has too much resistance in the seam area. It is very difficult to overcome it manually.

Important technical points in the manufacture of profile bending machines.

Bending a profile pipe with creases.

Pipe bender roller with a rib in the center.

If you bend a profile pipe on rollers without a side flange, then there is a possibility of bending the pipe with a screw. This is due to the fact that during bending the pipe can move and its position relative to the roller axis will not be perpendicular, but at some degree. To avoid these problems, you need to bend the profile pipe on rollers with guide flanges.

Profile bending.

The force that must be applied to bring the pipe bender rollers together and thereby bend the pipe depends on the distance between the rollers. In other words, the smaller this distance, the greater the force required to bring the rollers together. This is especially noticeable if the pipe bender is designed with a central movable roller and is clamped with a screw.

The distance between the rollers also affects the length of the pipe that can be bent on a given profile bender. Short pipes cannot be bent on a pipe bender that has a large distance between the rollers. For these reasons, the rollers on the profile bender are made so that they can be rearranged.

The smaller the diameter of the pipe bender rollers, the smaller the contact patch between the pipe and the roller will be and the greater the likelihood of the pipe slipping during bending. On professional pipe benders, rollers are made with a diameter of 100-200 mm, and they allow you to bend profile pipes of large cross-sections. For home use, rollers with a diameter of approximately 20mm are suitable.

The more drive rollers, the less likely the pipe will slip. If you are going to bend a profile pipe of large sections, then it is advisable to make two drive rollers.

If the central movable roller is pressed with a screw, then to facilitate its rotation it is necessary to place a bearing ball under it. Then the contact patch between the screw and the supporting part will decrease and it will be much easier to turn the screw. It is better to choose a screw with a trapezoidal thread rather than a metric one. Trapezoidal threads can carry much greater axial loads than metric threads.

Types of thread.

To bend round pipes you will need special rollers with a semicircular profile. If you bend a round pipe on straight rollers, it will flatten and instead of a round pipe you will get an oval.

Pipe bender roller for bending round pipes.

Making a volute pipe bender

The pipe bender should be assembled strictly according to the diagram. Check out the photo of a self-made pipe bender and different drawing options. Select a suitable diagram and adjust the dimensions if necessary.

Then follow these instructions:

• Weld the frame from channels (can be replaced with a thick steel plate or 1 channel of sufficient width).
• Mount the bearings on the shafts, which are then welded to the frame.
• Place the sprockets on the shafts and mount the chain on them.
• Cut out the guides for the clamping mechanism and weld them onto the frame.
• Mount the bearings on the clamp shaft and assemble the press mechanism. Use channels or thick steel strips as side restraints.
• Make a base for the bushing and weld it to the structure. Screw in the clamp screw.
• Weld a tubular driver to the upper end of the screw and the shaft.
• Lubricate the bearings and check the operation of the mechanism.

After installation, it is recommended to paint the mechanism to prevent the development of corrosion. To simplify the work, you can install a spring that returns the press to its original position.

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Making a machine yourself

Depending on what materials are on hand for self-installation of a pipe bender, the type of device is selected. The easiest way is to make a rolling front device.

It consists of the following parts:

• Shafts, which can be made of metal, wood or polyurethane (the choice of material depends on the strength of the profile products that will need to be bent);
• Chain for driving the machine;
• Axis of rotation;
• Mechanism for moving shafts;
• Metal profile for the structure frame.

The principle of operation is that if you insert a pipe between the shafts of the device and turn the handle attached to one of them, the shafts will move and the pipe will take the required shape.

To make a pipe bender, you will need a drawing of it

In order to make the unit with your own hands, you need to prepare the following components:

• Metal profiles;
• Jack;
• Several durable springs;
• Three rollers;
• Pen;
• Drive chain.

Shafts connected by a chain allow tubular products to be bent. To make it convenient to operate the device, you need to additionally screw on a handle to control the rollers. Manufacturing is carried out according to a certain scheme.

The frame of the device is made, the metal profile for it is attached by welding or bolts, and a vertical support is made on the side and in the center. Rollers are installed: one is lower, and the other two are higher, the distance between them is selected based on the bend of the pipe that needs to be obtained. A chain is installed that will drive the mechanism; it can be removed from old equipment, for example, a motorcycle. The handle is welded to the movable roller to set the mechanism in motion. A jack is installed under part of the profile with a roller.

The pipe bender is ready. Now you can bend tubes on it, adjusting their bending radius during operation.

Device

Pipe benders come in different drive types and designs, but they have one thing in common: the use of mechanical force that deforms the pipe in the required way. Structurally, such units include the following elements:

• Steel frame on which the bending mechanism is mounted;
• Durable metal strips, fixing rollers;
• The rollers themselves, which serve to fix the workpiece;
• Clamping mechanism with a punch of the required curvature and radius;
• Supports that support the system above the floor for ease of operation.

This description is just an example, since depending on the type of drive and the source of force that bends the pipe, pipe benders have significant differences in design.

Make your own crossbow pipe bender with a punch

They are called pipe bending machines because of their similarity with a type of weapon such as a crossbow. Only instead of arrows, a hydraulic jack is used, acting on the profile or pipe, bending them. To construct a crossbow-type pipe bending machine, you will need to use a welding machine. To implement the idea you will need to perform the following steps:

1. A frame of a cone-shaped design is manufactured. For this, corners, channels, profiles, etc. are used.
2. Two steel plates are connected using movable rollers, through which the part is bent
3. Inside between the rollers there is a jack on which a C-shaped shoe or punch is placed
4. The shoe must have grooves to prevent the tube or profile from slipping

This is interesting!
You can buy a punch or make it yourself.
For manufacturing, you will need a tube from which the seat for the material to be bent is made. It is recommended to use such pipe benders for bending pipes, since other shapes of products will simply be deformed using such a machine. It is not difficult to make such a device, but you will need a hydraulic jack for this.

The video below shows how to make a crossbow pipe bender on your own.

https://youtube.com/watch?v=YoG0d5OqeCc%3F

What is a punch

The punch is one of the most important components of a pipe bender. It is also called a shoe. You can make it from any available materials. To make a metal shoe, you need to take a thick-walled steel pipe, slightly larger in size than the profile one, which needs to be bent. The pipe for the punch is cut lengthwise on a milling machine or with a grinder into the required length elements. Then the resulting part is bent and the ends are welded to a metal ring. Next, the punch can be attached to a pipe bender and used for its intended purpose.

Compared to factory punches, homemade shoes have a number of advantages:

• Cheapness of the part;
• Structural strength;
• Long service life;
• Ease of installation and minimal time costs;
• Reliability.

The pipe bender can vary significantly in size.
The metal punch will be more durable and strong, and it is also very easy to make.

Designs of homemade devices

The simplest option available to most novice craftsmen is bending pipes according to a pre-made template. This method is used when it is necessary to obtain a large number of blanks of the same type.

Bending a pipe using a wooden template is the easiest way to solve the problem

As a template, you can use a structure made of wooden boards. The thickness of the wood is chosen based on the diameter of the pipes being bent - the board should have a margin of 2-3 cm. To prevent the metal profile from sliding off the template during work, the ends are processed with a slight slope.

The structure is attached to the floor or other surface in any way, installing a stop for the pipe nearby. Having inserted the profile into the gap between the template and the thrust element, smoothly and carefully press on its other end, pressing the pipe against the template. To ease the pressing force, you can use a lever of a suitable size or install a winch.

A winch can facilitate the process of bending pipes using a template

In a similar way, you can bend a metal profile of small diameter. If it is necessary to change the configuration of a pipe larger than 1 inch, then the template is made from sections of powerful fittings. To do this, holes are made in the concrete slab along the required trajectory, into which guides are inserted in the form of pins from sections of pipes, fittings, etc. The bending is performed by securing the edge of the metal profile by welding.

The advantage of this method is its cheapness and simplicity, however, the accuracy of the resulting blanks and the quality of their processing leave much to be desired. In addition, the template will have to be made every time you need to obtain a bend of a different radius.

Factory-made snail pipe bender

To produce a large number of similar workpieces with a small radius of curvature, you can use a snail pipe bender. This unit consists of two pulleys (wheels) of different diameters, mounted on shafts. Having fixed the end of the pipe on the impeller, use a roller of a smaller diameter (drive wheel) to press the workpiece, simultaneously rolling it along the workpiece. As a result, the pipe bends around the surface of the large pulley, repeating its shape. The only drawback of this method is the impossibility of obtaining large radius curves.

The most versatile and practical are homemade rolling pipe benders (bending machines), in which you can set any angle of deformation of rolled metal. The simplest design of a rolling unit is a base with drive shafts fixed at a certain distance from each other. Pressure on the pipe is carried out by a movable roller, and it is drawn through the rotation of the drive shafts. Screw devices, jacks, winches and electric motors are used as power drives for such devices. The rolling machine is the most difficult to replicate at home, as it requires turning and welding. However, there are many variations of its design made by amateurs, which indicates the high popularity of this solution. With the help of such a device, bending of any configuration is obtained, and the process itself is often automated. The only thing such a device cannot cope with is obtaining a minimum radius of curvature of a metal profile over a small segment.

What is it and what is it for?

A pipe bender (pipe bending machine) is a special device designed to give a straight section of pipe a curved shape.

The easiest way to bend a pipe, if it has a small diameter, thin walls and is made of relatively soft, plastic material, is to bend it with your hands.

But besides simplicity and speed, this method has no other advantages.

A steel tube with a wall thickness of more than 2 mm is no longer susceptible to the muscular strength of the average man. The radius of the bending curve is uneven, and there is a danger of the pipe flattening at the point of deformation.

A pipe bender solves two main problems - it makes pipe curvature predictable, and also compensates for insufficient muscle strength with technical devices. The scope of application of a pipe bender is very wide. It becomes the main tool where the pipeline appears - that is, where liquid or gas is supplied through a hollow pipe.

Heating, water supply, sewerage, air conditioning - this is not a complete list of areas where a pipe bender can be used. It is also used in various designs and mechanisms. For example, motorcycle exhaust pipes, a car muffler, bicycle handlebars, sports equipment frames, and greenhouses are all examples of the use of a pipe bender.

Example of work

Do-it-yourself manual pipe bender for profile pipes

To bend a profile pipe with small cross-sectional dimensions without a pipe bender, craftsmen use templates of the desired curvature made of metal or wood. The workpiece is pressed manually to the edges of the segment, rigidly fixing one end.

Wood template

The thin-walled element can be deformed when heated. Heat the area with a blowtorch to a temperature of 350-400°C and, using manual force, give the profile an arched shape.

If using simple methods is not allowed by the product parameters, you can design a manual roller pipe bender for a profile pipe. It is used to make arches and arcs for canopies, greenhouses and other structures of complex shape.

Required materials and tools

To make the device, you will need:

• channel No. 8 or No. 10 for a rigid frame;
• 2 hardened steel rollers with steps for profiles of different heights or restrictive rings;
• roller with notches for the movable shaft;
• finished bearing units;
• 2 or 3 gears or sprockets;
• steel chain;
• clamping screw;
• thin pipe for the gate;
• lever;
• welding machine;
• drill;
• "Bulgarian";
• hammer.

You also need cotter pins, nuts, threaded bushings, and washers. To process the finished structure you will need paint and lubricant.

Blueprints

The drawing is the basis that will help you make a pipe bender without making major mistakes.

This is especially important when working with metal labor-intensively.

Ready-made drawings are available on the Internet. Having sufficient experience, they are easy to understand and adapt to your capabilities.

You can imagine an approximate structure of a pipe bender by studying a factory analogue, and then develop a detailed diagram of your model.

Drawing and general view of a hand tool

Construction assembly stages

Sequence of operations for making a homemade roller pipe bender:

1. Cut the channel to the dimensions of the posts and base.
2. Drill holes in the frame parts to mount the rollers.
3. Weld a support frame with racks from a channel.
4. Cut and weld a housing from the channel with holes for installing the drive roller. The shaft should rotate easily inside.
5. Secure the clamping screw to the resulting box using bearings. Drill a hole in the top of the screw for the collar.
6. Insert the housing with the drive roller between the posts. The structure must move freely vertically. Secure the cover with a screw nut on top.
7. Screw the bearing units to the frame.
8. Insert the collar into the hole in the clamping bolt.
9. On the outside of the shaft axis, place the gears on a key or split cone bushings with nuts. Attach the third “star” to the stand. Put on the chain and press in the sleeve for the handle.
10. Conduct trial tests and make adjustments if necessary.

The last step is to disassemble, clean the metal from burrs, paint the fixed parts, and reassemble. Units that are subject to friction during operation should be treated with Lithol or other thick lubricant.

Ready homemade machine

To bend the workpiece, it is placed on stationary rollers, the pressure screw is lowered all the way and pulled using a rotating handle alternately in one direction and the other.

After each rental, the screw is tightened with a collar. When the arc acquires sufficient curvature, the screw nut is secured with a lock nut. This will allow you to bend several arches with the same radius.

This homemade pipe bender can even be used for professional purposes. It can handle profiles up to 60x60 mm in size or 3 pipes with a cross-sectional width of 20 mm at the same time.

Details of the handloom manufacturing process can be seen here

https://youtube.com/watch?v=W3SXjpAF1GM

Types of methods

A pipe bender for metal-plastic pipes is a basic machine that operates on one mechanics. The machine is indispensable for pipelines, including thick-walled and metal-plastic ones. It can work with different types of metal (steel, aluminum, copper, zinc and their alloys). For greater productivity, the bend areas can be pre-red to release the metal, relieve internal stress and make it softer.

Cold method

Common in garage craftsmanship. If you don’t have a blowtorch or burner, you can use it. The disadvantage is that it requires more effort. Cold metal is harder and can crack. Therefore only suitable for raw steel and soft non-ferrous metals. Safer compared to hot rolling, since you don’t have to work with high temperatures.

Hot method

Requires a torch and blowtorch. Heating relieves stress from the metal and therefore it becomes more pliable, but this is only relevant for thin-walled pipes. Thick-walled tubes cannot be heated to more than 300 degrees in a garage.

Types of pipe benders

Depending on the design, type of drive, cost, all pipe benders are divided into the following types:

• An angle pipe bending machine is the most common and simplest type of this tool. Used for bending pipes and profiles of various sections and diameters.
• Manual – portable compact tool. A manual pipe bender is used for small-section profile pipes.
• Hydraulic – used for profile and round pipes of various diameters. Thanks to the smooth bending process, such equipment allows you to obtain products of the highest quality.
• Electric is quite bulky, complex and expensive equipment. Designed for high-precision work. Used for production purposes.

It is not practical to buy expensive professional models of electric and hydraulic pipe benders for such needs.

Hot bending

This method allows you to give the corrugated pipe the required shape without the risk of cracks and flattening. The bend lines are smooth. This method cannot be used only for zinc pipes, since during the heating process the galvanized layer burns out, which serves the function of protecting the structure from corrosion.

Required tools and materials:

• quartz sand;
• wooden plugs - 2 pcs;
• gas welding (torch);
• drill.

Instructions:

1. The corrugated pipe is plugged with a wooden peg on one side, then quartz sand is poured in and the opposite side is hammered in the same way. This is necessary in order to avoid deformation during the pipe bending process. Without the use of sand, the construction material will be damaged.
2. At one end of the professional pipes a hole is made through which air will escape during the heating process.
3. The place that needs to be bent is heated using gas welding or a torch, and then the corrugated pipe is given the desired shape . When working with gas welding, all fire safety measures must be observed. It is necessary to avoid overheating of the metal, which can lead to the appearance of scale and deterioration in the performance of the product.
4. As soon as the pipe product has acquired the desired bend, it is necessary to remove the wooden wedges and pour out the sand. The plugs can be easily pulled out by heating the ends of the corrugated pipe with a burner.

How to make a pipe bender with your own hands: instructions

If you have an example or diagram of a pipe bender, then making the machine yourself will not be difficult. You must adhere to the appropriate sequence of actions. To make a pipe bender for a profile pipe, the following manipulations are performed:

1. On the shaft you need to place gears, as well as bearings and rings. The production of shafts is entrusted to an experienced turner. If you plan to create all the parts yourself, then you will need three shafts, two of which are distributed on the lower base (a channel serves), and the third is suspended on springs.
2. The corresponding holes are drilled in the rings, which are needed in order to cut the thread. This thread is needed to attach gears to the shafts.
3. The shelf for securing the third roller is also made from a channel.
4. All elements are distributed on the frame and combined by welding or bolted connections.
5. The first step is to install the frame on which the corresponding structural elements are distributed.
6. The shelf is welded perpendicularly to the base.
7. A handle is attached to one of the shafts.
8. Finally, to adjust the bending radius of the profile pipes, you need to install a hydraulic jack on the top shelf.

If you make a tool according to a template, then there will be no difficulties

To clarify some points, you should pay attention to the following factors:

1. The pressure shaft located on the shelf must be additionally secured to it. It is also secured with dowels.
2. The pressure roller is made by performing the following manipulations: a shaft is fixed to the shelf, as well as springs that are attached to pre-installed nuts. After making the shelf, it can be welded to the frame of the main device.
3. To tension the chain, you need to use a magnetic corner. It will serve as a holder.
4. The sprockets are fixed with dowels made from Grover.
5. The drive handle is constructed from a steel tube.
6. The jack is placed on a hanging shelf.

The design of the simplest homemade unit for bending profiled pipes is presented in the video below.

Crossbow pipe bender step by step design instructions

The crossbow bender got its name because it resembles the shape of a hand crossbow. The cost of crossbow devices is about 10 thousand rubles. To save on the purchase of such a unit, it is recommended to make it yourself.

The photo shows two options for crossbow devices for bending pipes. The first option is a factory design, and the second is a homemade machine. The difference between these two machines is significant, since the factory version is made of steel measuring no more than 2 mm, while for the homemade one, metal 3-4 mm thick was used. This means that the homemade unit was made not just to have it, but for everyday use.

Feeling the difference, every master will want to acquire a crossbow pipe bender, making it himself. The disadvantage of this version of the pipe bender is the fact that it allows you to bend the corrugated pipe at only one point. This is due to the fact that the device is equipped with a fixed shoe. This option is used for round pipes when you need to obtain a certain bending radius in one place.

To construct such a device, you need a channel and a hydraulic jack. A special shelf is made for the jack in which it is installed. In the upper working part, two rollers made of steel pipe are mounted between two channels. The distance between the rollers and the heel of the jack must be the same in order to be able to obtain even and neat bends.

For profile pipe

Profile pipe is often used to assemble the frames of greenhouses, gazebos, gates and wickets, canopies and much more.

Therefore, the owner of a garage or summer cottage sooner or later faces the question of how to bend a corrugated pipe at home.

A pipe bender will come to the rescue.

However, ready-made solutions cost a lot of money. Therefore, the best option is to do it yourself.

To make such a device you will need the following tools:

• Angle grinder, in common parlance – grinder;
• Drill with a set of metal drills;
• Welding machine, best of all – a household electrode inverter;
• A set of keys or sockets.

Before starting work, you need to draw up a drawing of the future bending machine so that all the parts relate to each other.

The main elements of a home pipe bender are:

• Frame welded from a steel channel or I-beam with a thickness of at least 4 mm;
• Roller shafts;
• The videos themselves;
• Sprockets for connecting a chain drive;
• Drive chain from an old bicycle or timing gear;
• Screw lowering the pressure roller;
• The rotation handles for the pressure screw and shafts are a hollow steel tube or a solid rod;
• Various accessories: nuts, bolts, washers, grommets, cotter pins.

It’s worth mentioning right away that if you don’t have rollers and shafts in your arsenal, it’s not possible to make them yourself without a lathe. As a last resort, you can cut the existing metal rods to size and sand them down. Barrels with an internal hole can be used as rollers.

With central roller

The sequence of actions when assembling a homemade pipe bender with a central pressure roller will be as follows:

1. Using a grinder, cut the channel or I-beam into pieces of the desired size. Tack them pointwise, and then, when the frame is ready, weld along the entire length. Afterwards, for aesthetic reasons, you can grind the seams with a grinding wheel.
2. Provide either legs from scraps of the same channel, or mounting holes for bolts that will allow you to clamp the machine to the workbench.
3. Drill holes for the shafts. Also, using a drill and grinder, make slits in the vertical part of the frame. The pressure roller shaft will move up and down in them. Insert the shafts with the rollers on into the holes made and secure them with cotter pins.
4. The threaded connection between the pinch roller rod and the blind frame is made either using a lathe or using a tap. Remember that large diameter threads are very difficult to cut. Be sure to use drill or other cheap lubricant when cutting threads.
5. Carefully grind off the outer part of the shafts on both sides so that the sprockets can be put on them. Put on the chain with a slight slack; if you make the grip too tight, additional force will be spent on overcoming the resistance.
6. Attach a lever to one of the shafts - to secure it, use the same lock as for the sprockets. If you want to strengthen the lever on the shaft, drill a hole and cut the internal thread. After screwing the bolt in, the lever will lock, and by unscrewing the bolt, the lever can always be removed for transportation. By rotating the lever, you can pull the workpiece through the rollers. By tightening the clamping screw, you can change the radius of curvature of the bent pipe.

Drawings and dimensions of a homemade structure:

Types of pipe bending devices and mechanisms

Nowadays, you can find examples of pipe bending equipment that have different designs: from relatively simple devices for manual bending to homemade machines with manual or electric drive.

According to their purpose, pipe benders are divided into two types.

The first type is angular (they allow you to give the desired radius to a certain area of ​​the workpiece).

The second type is three-roll pipe benders - machines and devices that allow you to form a given bending radius along the entire length of the workpiece.

Depending on the method of adjusting the radius, pipe benders are mechanical.

And hydraulic.

The support shaft drive can be either manual or electric.