How To Make Rectangle Tube Bends WITHOUT a Bender in ANY Size + Radius!!
Summary
TLDRIn this video, the host demonstrates how to create a rectangle tube bend using a DIY approach, perfect for custom fabrication projects. Despite the challenging 'hard way' method, the tutorial shows a step-by-step process of bending hollow structural steel into a tube donut. The host uses spacers and a welding tank to achieve the bend, emphasizing the importance of smooth cuts and consistent welding for a professional finish. The result is a reusable template for creating custom tube bends, showcasing creativity and resourcefulness in metalworking.
Takeaways
- 🎥 The video is a premiere of 'Metal Reborn' at a twilight drive-in, which has been a huge success despite the weather.
- 🌐 'Metal Reborn' is also available online for viewing at metalreborn.com.
- 🔩 The video tutorial focuses on making a rectangle tube bend the 'hard way', which involves more material to bend compared to the 'easy way'.
- 🛠️ The presenter demonstrates how to create a tube donut using welding techniques to bend rectangle tubing.
- 👷♂️ The motivation for the video is to explain how the floor bracing for a model 8 was made, which required custom bending of rectangle tubing.
- 🛠️ The process involves creating spacers to hold materials at the right height for bending.
- 💡 A welding tank is suggested as an alternative to a roller for bending flat bar into circles, showing creativity in the absence of specialized tools.
- 🔨 The importance of smooth cutting with a plasma cutter is emphasized to minimize slag and ensure a nice, clean circle.
- 🔩 Clamping and spacers are crucial for accurate assembly of the rectangle tube.
- 🔥 Welding is done using a small 110 welder, demonstrating that it's possible to achieve quality results with basic equipment.
- ✂️ After welding, the tube is cut and ground to create a smooth, finished tube bend that can be used for various structures.
Q & A
What is the event being discussed in the script?
-The event being discussed is the premiere of 'Metal Reborn' at a drive-in theater.
What is the website mentioned for checking out 'Metal Reborn' online?
-The website mentioned is metalreborn.com.
What is the purpose of the video tutorial in the script?
-The purpose of the video tutorial is to teach viewers how to make a rectangle tube bend using a homemade method.
What is referred to as 'the hard way' in the context of bending rectangle tubing?
-Bending rectangle tubing in a direction that requires more material to bend is referred to as 'the hard way'.
What is a 'tube donut' as mentioned in the script?
-A 'tube donut' is a term used in the script to describe a circular shape made from bending a rectangle tube, which can be cut into various angles for different structures.
What is the motivation behind creating the tube donut as explained in the script?
-The motivation is to replicate the floor bracing for the model 8, which requires bent 1x2 rectangle tubing.
What is the significance of the welding tank in the script?
-The welding tank is used as a substitute for a roller to help bend flat bar into a circle without specialized equipment.
What is the importance of being smooth when using a plasma cutter as mentioned in the script?
-Being smooth with a plasma cutter is important to achieve a nice, clean cut with less slag and easier cleanup.
What technique does the script suggest for welding corner joints?
-The script suggests using the whip and pause welding technique for corner joints, which involves welding on the corner edge to create a radius on the weld.
What is the reason for leaving a gap when cutting the sizes for the weld?
-Leaving a gap is important for structural welds to ensure that the joint can be filled with weld material effectively.
What are the steps involved in grinding the weld after it has been made?
-The steps include grinding the flats, grinding the corner at a 45-degree angle, and then rounding it out to be consistent all the way around.
Outlines
🎥 Premiere of 'Metal Reborn' and Introduction to Tube Bending
The speaker begins by greeting the audience and informing them about the premiere of 'Metal Reborn' at a drive-in theater, which has been a success despite bad weather. The video is also available online. The speaker then references a previous video on making circles with a plasma cutter and introduces the topic of the current video: making a rectangle tube bend the 'hard way'. The hard way refers to bending the tube in a direction that requires more effort due to the shape of the rectangle tubing. The goal is to create a tube donut that can be used as a template for various structures. The speaker also mentions the motivation behind this video, which is to explain how they made the floor bracing for a model 8 using this technique.
🛠️ Preparing for the Rectangle Tube Bend
The speaker describes the process of preparing to bend the rectangle tubing. They plan to weld spacers onto all four sides of the tube to create a donut shape. The spacers are made from three-quarter-inch square bar and are used to hold the tube at the correct height for bending. The speaker emphasizes the importance of being smooth when cutting circles with a plasma cutter to minimize slag and ensure a clean cut. They also discuss the use of a welding tank as an alternative to a roller for bending the flat bar into a circle.
🔨 Assembling the Tube Bend Structure
The speaker demonstrates how to assemble the tube bend structure using the spacers and clamps. They aim to create a 1x2 rectangle tubing dimension using 10-gauge material. The spacers are placed to ensure the tube is bent into a circle with the correct dimensions. The speaker also discusses the importance of accuracy in the assembly and the use of a square to ensure the pieces are aligned properly. They mention the need to leave a corner joint for welding, which will result in a stronger structure.
💥 Welding the Tube Bend
The speaker proceeds to weld the tube bend, starting with tack welding at various points around the structure. They emphasize the importance of keeping the clamps on during welding to minimize distortion from the heat. The welding is done using a small 110 welder, and the speaker uses the whip and pause technique to ensure a clean and strong weld. After welding, they remove the clamps and spacers and prepare to cut a piece out of the 'donut' to create the final tube bend.
🛋️ Completing the Tube Bend and Final Thoughts
The speaker completes the tube bend by cutting out a section of the donut and finishing the weld on the inside. They use a die grinder with a drum sanding wheel to create a smooth radius on the inside of the bend. The speaker reflects on the process, noting that while it is time-consuming, the result is a reusable template that can simplify future fabrication projects. They encourage viewers to watch the video and try the technique for themselves. The speaker also promotes the online availability of 'Metal Reborn' and other related content creators.
Mindmap
Keywords
💡Plasma cutter
💡Rectangle tube bend
💡HSS
💡Spacers
💡Welding tank
💡Tack welding
💡Whip and pause welding technique
💡Milling scale
💡C-clamps
💡Die grinder
💡Cubatron discs
Highlights
Premiere of 'Metal Reborn' at a drive-in theater was a huge success despite bad weather.
The film 'Metal Reborn' is now available online at metalreborn.com.
Introduction to a tutorial on making a circle tool with a plasma cutter.
Explanation of the 'easy way' and 'hard way' to bend rectangle tubing.
The motivation behind creating a video on making floor bracing for a model 8.
Demonstration on how to make a tube donut for cutting up and using in various structures.
Use of welding spacers to hold materials at the right height for bending.
Innovative use of a welding tank to bend flat bar without a roller.
Importance of smooth operation when using a plasma cutter to avoid slag.
Cleaning mill scale and slag off the metal before welding for better results.
Clamping and spacing the materials to create a 1x2 rectangle tubing.
Bending the flat bar into a circle shape with the help of a hammer.
Using a small 110 welder for precision welding of the tube donut.
Technique of welding on the corner edge for a smoother finish.
Cutting a piece of the pie from the tube donut for further processing.
Grinding the weld with different grits for a smooth and consistent finish.
Using a die grinder with a drum sanding wheel to achieve a nice radius on the inside of the tube.
Completion of the tube bend and its application in fabricating floor inner structures.
Promotion of 'Metal Reborn' being available online for free and other related YouTube channels.
Transcripts
hey guys
what's up
[Music]
how's it going
so here we are at the premiere of metal
reborn on the big screen twilight
drive-in it's turned out to be a huge
success there's tons of people coming
out despite our bc weather
now it's available online for you guys
to check out right here on
metalreborn.com
welcome back to make custom everybody
you may or may not have seen one of our
previous videos on making circles with
the plasma cutter if you have not go
check it out i teach you how to make a
circle tool so that you can make stuff
like this so what these are and what
this video is about is how to make a
rectangle tube bend the hard way what i
mean by the hard way you may not know
that reference if you're bending hss
hollow structural steel like rectangle
tubing there's an easy way and a hard
way the easy way is pretend this is
rectangle tubing if you were to bend it
this way
like this that would be the easy way
it's got uh you know less material to
bend if you were to bend it like this
that would be the hard way
what i'm gonna do today is show you how
to make a tube donut that you can cut up
and use the radiuses to make
whatever structure you want to make and
the motivation behind me making this
video is a couple of people asking about
how i made the floor bracing for the
model 8. now christina hopefully you can
find a couple clips to put in there for
the floor bracing and the model a it's
got nice bent 1x2 rectangle tubing for
the floor bracing makes it look really
nice i did the exact same thing what i'm
doing today to make that i had to make
my own rectangle tube bend that i could
cut up as if it were an exhaust tube
bend so that i could make that floor
structure here are the donuts that we're
gonna make this tube bend out of
basically what we're gonna do is we're
gonna weld these on all four sides it's
a lot of welding and a lot of finishing
but if you do it nicely it's so so worth
it in order to kind of make this happen
without it going uh in a weird direction
i'm going to make a bunch of spacers to
clamp in between these two to hold them
at the right height so that we can bend
some flat bar and make our circles all
the way around you might be wondering
what the hell that tank is that tank is
going to help us bend
our flat bar because not everybody has a
roller i've got a roller back there that
i could
just feed this through it'd make a nice
little ring and you guys would all be
like oh well i don't have a roller well
you don't need one no excuses you can
just use a welding tank or anything it
doesn't matter there's always a way to
figure it out so i'm going to cut a
bunch of these pieces of three quarter
inch this is just something from the
scrap bin three quarter inch square bar
i'm gonna just put a few pieces
in there that we can clamp in
and clamp this thing together while we
wrap it tack it weld it
make it happen come along
[Applause]
we've got some spacers cut here i'm just
going to clean up the edges deburr them
a little bit
[Music]
now these came fresh off the circle
cutter you know i just want to reiterate
when you are circle cutting with that
type of a cutter you have to be as
smooth as you can be you saw me i kind
of like started here i started with
myself turned over and kind of worked my
way around it's important that you can
do a full sweep without having to be
jerky and stop that way you get a nice
smooth
circle out of there also less slag if
you're nice and consistent with a plasma
cutter you don't get as much slag it's
the same thing with a torch it's funny
when you see somebody torch with
oxyacetylene and you get all that
terrible slag well if it's held in like
a cnc or if you're really really smooth
with it that slag falls off same deal
here so less lag less cleanup try and be
smooth i'm just gonna clean these up and
get the mill scale and slag off there
isn't much slag but when you're tig
welding mill scale like this brown stuff
that can affect your weld i'm not saying
that you have to tig weld this stuff
it's just nice when everything's clean
[Music]
okay so now we can start clamping these
pieces
together spaced apart now i'm trying to
make 1 by 2
rectangle tubing or as close as i can
get to it so this is 1 8 material it's
actually a tiny bit thicker than 1 8
it's 10 gauge but it's fine for what
we're gonna be using this for
demonstration so i'm gonna put these
three quarter inch blocks three quarter
inch plus one eighth plus one eighth one
inch these are inch and three quarter
wide so that plus one eighth plus one
eighth will be two inches so we're gonna
go two inches this way one inch this way
and that is a rectangle tube this is the
hss tubing that we would be using with
something like this so it's one inch
here two inch there and uh if you were
gonna make bracing with this type of
material it's a great size that's why
we're making the bend now i need to
clamp this all together
okay we've got our spacers in place
kind of like that
i'm going to start clamping
you're going to want this to be pretty
accurate so i leave the clamps just just
a little bit snug so that we can kind of
tap around with a hammer after make sure
that we're as perfect as we can be
so just a little snug this will be a
little bit easier on us
put the c-clamps on the inside
and we'll do the outside first
[Applause]
so using a square i'm gonna
line these up you can see
how we're not quite there yet
we're gonna have to move it over a
little bit so i'm gonna
make sure these are loose
check it in a couple of spots
and i think that's pretty good
so we're squared up top and bottom
now i'm gonna bust some of the slag off
of this piece
i didn't have enough flat bar
i got most of it
quick grind on this piece of flat bar
here okay so i'm just going to bend this
thing around here
it's a little bit tighter of a curve
than we really need but we should be
able to spring it back a little bit
and use a hammer just to try and get
some of these flat spots out of it as
well
okay
we are getting pretty close
to what we want to see
this little flat spot here
a little tight spot there
i'm just finagling it a little bit
trying to get as close to a circle as we
can get and then the rest of it will be
able to just kind of clamp and and tweak
and and work as we go around this circle
there is a little bit of overlap here i
will have to cut off
but for the most part it's pretty good
i'm trying to leave
a bit of a gap not so much a gap but a
corner joint for the weld i think it's
important especially if it's going to be
something structural like you want to be
able to fill that up
with weld that's why i've cut the sizes
that i've cut this is three-quarter
these are an inch overall
and an eighth of an inch on each joint
there so that is why i've left that
corner joint it's just a way stronger
well
all right i'm gonna bust out bust out
the baby welder today
this is just a little 110 welder i'm not
using big guns on this
jacked it all the way up for this
thickness material you can
you can jack a 110 welder all the way up
for it so i'm going to pick a spot where
i think
it looks really good
as far as
fit i mean quite a bit of it does look
pretty good
i'm gonna double check
square on here
i mean that looks that looks pretty good
it's fitting nice and tight
nice and square
we've got attack down there we're going
to attack
right there
[Music]
all right so we made it
most of the way around there i'm just
going to trim off the end of the circle
here
now we should be able to
close that up
just like that
[Applause]
[Music]
right
uh actually
getting ahead of myself
i want to leave the clamps on
while we weld it
reason being
is that that heat from welding is going
to want to start doing stuff
and the least amount of stuff it does
the least amount of mess up it'll be
if that makes sense okay i'm going to
i'm going to attack a few more spots
then i'm going to do a grind and then
we're just going to weld the crap out of
it so let's tap a few more spots here
[Music]
let's weld it
[Music]
[Music]
all right we're all done welding have a
look at that i welded right on the
corner edge just like i said
this is the whip and pause welding
technique that i have talked about
before in a couple of the other videos i
like doing open root corner joints like
that it's
nice to have a radius already on the
weld it seems like there's a little bit
less grinding that way but that's with
meg you could take it and it'd be the
same thing so what i'm going to do now
i'm going to unclamp it i'm going to
take out our little spacers that are
everywhere since we don't really need
those anymore and then we are going to
cut a piece of the pie so to speak i'm
not going to actually weld in the inside
of the donut now the reason being is
that it's just really difficult to grind
that quite nicely so what i like to do
when i'm making these is leave it where
it's at i'm going to grind these edges
nice and then we're going to cut the pie
as if we're going to use a chunk of it
and then i'll show you how to put in the
inside piece finish it off and
we'll have our finished tube bend
ooh this thing's hot still atsui
means it's hot isn't it in japanese one
of the four things i remember how to say
these might be in there pretty good so
we can pry them out of there have too
much trouble
they're
they're really in there
they don't want to come out when i cut
it open i guess i'll get those out of
there it'll be easier
okay i'm going to grind it up just use a
3-inch ankle die grinder i know a lot of
people are asking me like what's what
kind of die grinder do you use
like the cheapest one ever harbor
freight in america or princess auto here
these are just the cheap ones that you
can get there i love them i mean i use i
run my compressor pretty hot like not at
90 psi i run it at like 110
so kind of any grinder is gonna work
really good at 110 psi so i just buy the
cheap one our princess auto i don't know
about harbor freight but if you break a
tool that you bought at princess auto
and you go back and be like i broke this
they're like here you go here's a brand
new one bye you know i don't know why
they do that but they do so and i never
really break them so that's what i use
as long as you keep them oiled they're
fine
speaking of which there's a couple of
drips to this guy got a lot of grinding
ahead of it today if you're looking for
good discs these are the ones i use
these are called cubatron discs they're
from 3m this is not a paid advertisement
i'm just telling you what i use they are
the best disc i have ever used period
nothing has touched them yet if you have
discs that you sell send me some i'll
try them out against these
good luck because these are the sharpest
discs ever they're very expensive they
only come 15 in a box i think they last
about three times longer than pretty
much anything else so if you're looking
for good discs they're expensive
but you get more than you pay for i'm
going to go at it with 36 grit to cut
the weld down
then 80 grit and then we'll give it a da
just real quick the way i like to grind
stuff like this that kind of matters too
so i figured out i'll just quickly
explain it i'm going to grind really
flat
get the edge of the weld off until it's
flat like like i've done there and i
stop right there you don't want to go
any farther than that and then i'm going
to grind the outside same thing right
till i hit the parent metal and then i'm
going to grind on a 45 all the way
around and you can see
really how consistent you're being nice
camera work there i saw that pan out
nice
you can see how totally consistent
you're being so you grind the top grind
the side then you've got almost a 90
degree angle and then you can grind that
on a 45 and you can really see how wide
your 45 degree grind is and make sure
that that's even all the way around
that's how you know that it's even i
think that some guys overlook explaining
that because it took me a while to
really kind of get that down like those
little things kind of help when when
you're doing stuff like this for your
end product so
grind the flats grind the corner and
then start rounding it out be as
consistent as you can be
[Music]
okay so i just wanted to show you what
it looks like
after i faced this side i faced all the
way around the edge stop as soon as you
get to the parent metal and by the
parent metal i just mean whatever the
weld is touching it's kind of a term and
then i went 45 degrees on here
and to make this consistent i just kind
of eyeballed how wide my 45 degree is
and tried to be as consistent as i could
all the way around
that way you've got a good starting
point for radiusing an edge like the
reason i say this is because i want a
consistent radius all the way around
like there's a consistent radius on this
tubing here that we're trying to mate up
to the next step is that i'm going to
change this to an 80 grit roll lock
that one right there and i'm going to do
the same thing but i'm going to go on
instead of a 45 degree angle i'm going
to do you know 22 and a half and then
whatever that one is and trying to be
consistent all the way around and that's
going to get us our radius so that it's
easier to blend just
be consistent with your grinding it's
kind of the key thing here
[Music]
okay we're all done grinding
we're still not done yet though i'm
gonna chop a chunk out of here and then
we're gonna finish the bottom and grind
that out and then we'll be done okay i'm
gonna chop it
here's a little tip
i don't know whether or not this is
going to pop in or pop out because now
we put a ton of weld into this piece if
you're using a zip cut and you've got it
all the way in there it could bite if
this thing goes and clicks in as soon as
you break through it could break a disc
so i know i've got a guard on there but
why let it jam right it could jam so i'm
going to finish it with a hacksaw
[Applause]
okay it popped out so it probably
wouldn't have bit our disc but could
have gone the other way
so i'm just gonna peel off approximately
a 90 out of it
[Music]
pop your spacer out okay now i'm going
to use this flat bar
a chunk of steel
don't ask me where i got this thing but
whenever i see
heavy hunks of different shapes for
stuff like this i just grab them and i
stick them in my dolly bin you never
know when you're gonna need it
let's see we're getting pretty close
okay i think we're just about there
yep
perfect
there it is
she's all closed up
it's a lot easier to
fit and weld that piece in if you
already cut your bend
so uh once again
with the pause technique when the joint
and the heat are perfect
you know you're filling just as much
material as uh as you need not too much
not too little so
that's hot it's easy to grind it off so
i'm going to grind that all up to grind
that inside area i'm going to use a die
grinder with a drum sanding wheel on it
that's going to help me kind of get that
nice radius in there and then we'll
finish it off with this and we're done
[Applause]
[Applause]
[Music]
cheers
[Music]
[Music]
all right here we are we're done there
is the tube bend this is what this is
all kind of working up to be
here is our piece of tubing check that
out that's what it's for
this donut you can cut whatever angle
you want finish the bottom edge
and then you can make your own
tube bends like that
so i hope you guys like this video this
is a technique that i've used a couple
of times it seems like it's a lot of
work but when you really think about it
yeah it took it took a few hours to make
this piece but
this one donut is enough pieces to do
the whole floor of that model a i
actually used up the whole 360 degrees
making the cross members in there so you
mean worse comes the worst that there's
a few hours and then it made your life
easier and more beautiful when you're
fabricating your floor inner structure
hopefully you guys like this tip thanks
for watching make it custom i just want
to say that metal reborn is now online
it's free for everybody to check out so
go to metalreborn.com speedline
filmworks they've got a youtube channel
as well check them out also bellows
customs they've got a 39 lincoln zephyr
three window coupe that's chopped and
it's deadly they've also built a ton of
sleds he's got a youtube channel bellows
customs there's this wicked time lapse
of him chop and i think it's a 37 ford
500 coupe just to kill our youtube
channel check him out i'm sure you'll
love it thanks a lot everybody don't
forget to like click subscribe hit
notifications and we'll see you on the
next video thanks a lot for watching
everybody
[Music]
you
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