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cage

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darrell

Well-known member
hey guys i was wondering how you get such a good radius on the bends on the cage i am getting ready to build one in a little while and i have no idea how to do it.

darrell
 
we just built a jig out of wood on two tables put together. Draw your arc on your table or you can even use the garage floor if you don't mind putting nails or screws into it. From here we just used 1 x 2s and screwed them on the insde of the arc that was drawn. Using conduit hold down clamps (home depot electrical section) screwed the middle of the pipe down in the middle of the arc. Bent one side putting clamps every foot or so then the other. Just work your way down one side and don't try to bend it all at once. We used DOM and didn't need to do anything fancy or even apply heat to the bend and had no creasing. Wether or not that applies to all tubing I can't answer.
I watched a guy do one a few weeks ago in a hydraulic bender it was smooth and looked awesome but how that guy did it perfectly every time is beyond me. My guess is hes just done so many its second nature but it was impressive.

EDIT - on the 1 x 2's we followed the arch all the way around about 3"s apart so you end up with a sun burst looking pattern.

EDIT 2 - this pic to me looks like a jig that diamondback has in their shop. Correct me if I am wrong fella's. First pic on this page with all the guys standing around it.
http://www.southernairboat.com/phpBB2/v ... &start=100
 
I use the channel ring off a fruit tub. Cut the channel and spread it apart 12" Then attach a catch at one end.It works good!!
 
I use a motorized roller. It makes a really sweet bend and works with Stainless, Mild, Aluminum and even square tubings. I have had it around for years, so it is what I use. However, all of the methods in the above posts will work also. They are simular to the method we used to use to bend wood also!
Ralph
 
Yes I made my motorized roller, actually I have built two. I will try to remember to take some pics of it next time I am over at the shop where I keep it. If you plan to build one yourself, you will need access to a lathe large enough to turn the rollers. Mine has one roller that is 12" in diameter and two smaller rollers, one on each side of the large roller. The large roller is the motorized roller and also the moveable roller.
FK
 
Another thought, If your close to an airboat builder they would probably
roll your hoops very cheap. They would match, be done right, be done
quicker, and there would be no waste. And as a bonus you would get to
meet some new air boaters. I've seen a lot of guys stop what they were
doing to weld a doodad, or fix a gizmo for a stranger. might be worth a try.
 
I would love to come down there and tour the airboat companies.
Problem is, it's about 1500 miles from here.
I'm going to do it sometime though.
 
I made a main hoop jig out of plywood. It is only 1/2 the arc so you have to braze the two pieces together at the top.

if the pic isn't here look in my gallery.

You just attach the EMT in the holder at the top end with the welded seem touching the plywood, lay the pipe on the ground and roll the wood arc. it made a nice smooth bend. I used one 10' piece for each side then cut off the excess. hope this helps.

Also most of the people i have talked to say brazing is best because it's (more malleable) flexes before it cracks.
 
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