Tools I am using to make a roll cage

[norvalwilhelm]

I have been working on my cage and this is the tube bender I am using. There is a big difference between a pipe bender and a tube bender. A pipe bender is the type that looks partly like a press and uses a die on a jack to bend the pipe up in the middle. This will not work for roll cages.
A tube bender grabs the tube and pulls it around a die with a guideing/supporting shoe.
This unit runs on a combination of shop air and hydraulic pressure. The shop air plugs into the hydraulic pack and uses it to produce 10,000 psi of hydraulic pressure. That is the yellow pack to the left.
The orange cylinder applies the pressure to the die. Each pipe size requires it own die and supporting shoe.

This is another shot with the pipe being pulled around the die.

This is the roll bar bolted in after welding for a test fit before adding the back bracing.

This is a homemade belt sander and 14 inch vertical disk. While not needed it really makes deburring and flattening cut edges easy

If anyone is interest I would start a post teaching others how to accurately use a tube bender. I expect and get 1/16 and better accuracy but you have to know your particular tube bender.
Anyone interested? I would start another post on how to learn your tube bender and some tips on how to make a better cage.

 

[Fuelie]

Norval,

How is your cage project coming along? Did you put in any front and rear braces? How does it look in the car?

Take care,
Brian

 

[norvalwilhelm]

Norval,

How is your cage project coming along? Did you put in any front and rear braces? How does it look in the car?

Take care,
Brian

Thanks for asking Brian. I just posted an update. The main part of the roll bar is finished along with the main hoop above the driver and passenger's head. this is already bolted and flanged to the roll bar.
I will next start on the down tubes by the window pillar and tie that into the frame. I will also run 2 per side side bars, one low and fixed and one high and swing oout.
I will also run bars through the firewall and up to the front suspension.
The main hoop over our head is tucked up into the Tee roof so no part of it shows through the side windows.

 

[vette-dude]

Thanks for asking Brian. I just posted an update. The main part of the roll bar is finished along with the main hoop above the driver and passenger's head. this is already bolted and flanged to the roll bar.
I will next start on the down tubes by the window pillar and tie that into the frame. I will also run 2 per side side bars, one low and fixed and one high and swing oout.
I will also run bars through the firewall and up to the front suspension.
The main hoop over our head is tucked up into the Tee roof so no part of it shows through the side windows.

What you are describing is Rotary draw bending process as opposed to compression bending. The resaon compression bending does not work well on heavy walled pipe is that it deforms the pipe at the Tangent point of the bend. This causes ovalarity of the pipe and sometimes splitting. It is okay for some applications but not for roll bars. Standard replacement muffler tubing is usually compression bent.

Rotary draw on the other hand gives a nice bend without the use of a mandrel provided you are doing large radi and have a genurous Centerline Radius (CLR). When the CLR's become less than 2D (2 times the dia.) then you would opt for a mandrel to make the pipe stay round and lessen wall thinning. There are many variables involved when determining this, i.e, wall thickness (WT), material to be bent, CLR, finish desired, etc. A good source of info is www.toolsforbending.com or www.omnibend.com or ww.hornmachinetools.com. I have worked in this industry as an application engineer and technical advisor for about 15 years and I would be happy to help you with any questions or advice. It looks like you have it under control and know what you are doing but just thought I would offer. Looks great.

Randy

 

[norvalwilhelm]

That's really nice Randy. You obviously know what you are talking about.
I don't know the mechanics but it seems to be working for me
Thank you for the offer
Norval