Bending square or angle on the cheap

[AmigoTJ44]

Looking to make some fenders using square or angle. What would be a cheap way to make the bends. The square will be 1". I found a die that will fit into a pipe bender but not sure how well that will work, but will be able to use it for other things on the cheap]. Also found a bender http://www.woodwardfab.com/woodward_fab_pipe_tube_fab_page.htm that isnt to pricey but thought I would hit everyone else up here to see what they have done. I am trying to get away without buying the tube bender set up just yet for $$$$ reasons.

[willyquasar]

Compact bender from Harbour freight. $69.00 on sale.
1" square tubing die from shopoutfitters.com. $139.00
The die will fit the bender and you'll get plenty of dies for bending solid stuff also. Bending the 1" is not that easy, but it can be done. I've built several tree stands with this setup.

[guidolyons]

Or if you don't feel like shelling out $$$ and just have a few bends to make, you can cut slots or small pie pieces out of the inner side of the bend, bend and then weld the slots back up. It's redneck, but will work for fenders or other non-structural type items. I wouldn't use the pie cuts on a cage though.

[Mud in the blood]

If U have a press U can make a little pusher die for bending 1" REAL eazy. That's how I do all my 1" square.

[braxton357]

Square tubing bender dies are pretty simple to make using some ~.25-.5" thick plate as well.

[Hickeyjones]

Your welcome
http://www.metalgeek.com/archives/2005/05/01/000047.php

[guidolyons]

Metalgeek.com...hmm Not bad...even if he is an artist. Jig is not a bad idea either, but MDF ain't going to work for anything much thicker than EMT conduit.
A steel jig welded to a steel table and a long cheater bar (a rosebud on the O/A torch wouldn't hurt either) would work well, though.

[TLCObsession]

Metalgeek.com...hmm Not bad...even if he is an artist. Jig is not a bad idea either, but MDF ain't going to work for anything much thicker than EMT conduit.
A steel jig welded to a steel table and a long cheater bar (a rosebud on the O/A torch wouldn't hurt either) would work well, though.

guido -

One of the Monster Garage or other Discovery shows on Jesse James showed him bending the spine of a MC frame on an MDF jig. I tried it with 1.5" .120 wall and was able to make a very nice gate top. You do need to heat the bigger tube, but short of a $2000 roller, its a great way to do it.

Jim

[guidolyons]

Yeah, I saw that one Jesse almost ripped his nuts off bending that frame spine. It was the motorcycle madness bike build episode on Discovery. I was thinking about that when I added the rosebud comment.

For smaller brackets and tabs, etc I just bend them in the vice, but a jig will help keep tube from kinking when you bend it, and/or keep it from bending too far. Although, there will be some spring back that will need to be accounted for.

For 1" square tube the walls are usually pretty thin, so there are many ways to bend it how you want it. I also like the conduit bender style that the guy on metalgeek.com made. Leverage is a wonderful thing.