78 GS 550E On going Project

[mike-s]

Tubing bender perhaps? link

[pete]

Makes sense, but I was hoping to avoid extra tools... maybe I'm just too naive

[mike-s]

You could always figure out the design and finalise your requirements and then go down to a place like steelpro, bendpro or look up a directory. link, radius. They should be able to do it for a reasonable cost. Or you could just call by a muffler shop that are accustomed to making up custom exhausts. Often they won't mind an odd job, though their mandrel benders may not be able to go down to a small enough size for your needs.

[pete]

True... but waiting to get time to get somewhere like that will have me eating my week off and not getting the fibreglassing done unfortunately.

If a bender is best, then there's a few on eBay that should be ok for around the $20 - 30 mark...

But I think I'd best stop threadjacking ITims' thread now

[mike-s]

hehe, oops. that's what i get for attempting to be helpful!

[ITim]

Na I don't mind the Threadjacking. I should have probably explained my process a little more anyways.
As for bending, I actually went with what you (Pete) had mentioned. All I did was use brute force on a solid round object for some of the bends. On the tighter curves I just used a bench vice, clamped it in and used brute force again. Because the bar is fairly flexible it was easy to do slight adjustments by hand if I had bent it too far or not enough.

Don't be too discouraged about it all, I'll be honest this was my first time attempting something like this. There were a few mistakes and a couple of re-dos, but it all works out. I have confidence that you can pull something off once you jump into it.

Also it was my first time welding something like this. I used a Mig welder, if that's what your house mate has then you'll be fine. It dosen't take long to get the hang of. It just might take long to perfect it, and I am a long way from that as well.

Oh, that was the other one... how many layers of mat did you go with? I would think 3 would be plenty strong enough with the wire mesh...

Yeah 3 layers will be plenty, I only used 2 and a good amount of bondo. Once the frame and aluminum mesh are on; it all feels really strong and the mat is more for just cosmetic.

[ITim]

Actually the support beam in this photo is what I mostly used for bending. I did slight bends to create a large curve, and also used it for tighter bends as well.

[pete]

hehe, oops. that's what i get for attempting to be helpful!

Mate all good, I appreciate it

Just didn't wanna take away from what this thread is about, that awesome lookin' 550 there

Na I don't mind the Threadjacking. I should have probably explained my process a little more anyways.
As for bending, I actually went with what you (Pete) had mentioned. All I did was use brute force on a solid round object for some of the bends. On the tighter curves I just used a bench vice, clamped it in and used brute force again. Because the bar is fairly flexible it was easy to do slight adjustments by hand if I had bent it too far or not enough.

Don't be too discouraged about it all, I'll be honest this was my first time attempting something like this. There were a few mistakes and a couple of re-dos, but it all works out. I have confidence that you can pull something off once you jump into it.

Also it was my first time welding something like this. I used a Mig welder, if that's what your house mate has then you'll be fine. It dosen't take long to get the hang of. It just might take long to perfect it, and I am a long way from that as well.

Cool, thanks for the detail! I was trying to picture in my head how one of those tube benders would get the gentle curves done and I couldn't do it as they seem to create such a tight radius, so that makes sense now.

As to the welder, it's a stick welder apparently, but I figured it should be ok given the small welds that will be required for this.

If all else fails, I have an angle grinder and a grinding wheel on the dremel...

Yeah 3 layers will be plenty, I only used 2 and a good amount of bondo. Once the frame and aluminum mesh are on; it all feels really strong and the mat is more for just cosmetic.

Ok cool, I figured most of the strength would be from the frame and mesh.

Actually the support beam in this photo is what I mostly used for bending. I did slight bends to create a large curve, and also used it for tighter bends as well.

The support beam in my garage is square rather than round, but I'm sure I can find something to work with around the place, and that will make it so much easier than trying to get a tube bender ordered and have it arrive in time and everything as well.

Thanks again for the details! I really wanna pull this off as it will solve a huge drama for me with the seat...

[Redneck]

Hey for you guys following the wire bending saga. I used that type of wire on my Medieval Helmets. Easy to bend. I like to use a ball pean hammer and a pipe fo the appropriate size for the bend leave on a about six inches of bar to hold on too and the bend the rest to the shape you want using the pipe and gentle easy taps on the hammer if you go slow you will see it form nicely. If you get impatient and go for big hits you may put in sharp bends you don't want. A vise is good for bending too, but you will find the bends not as clean. If you can find a piece of pipe or some thing solid enough in about the same curve pattern just tap away and don't be afraid to just use your hands at times to just squeeze it the right way. Hope that helps.

Paul

[pete]

Hey for you guys following the wire bending saga. I used that type of wire on my Medieval Helmets. Easy to bend. I like to use a ball pean hammer and a pipe fo the appropriate size for the bend leave on a about six inches of bar to hold on too and the bend the rest to the shape you want using the pipe and gentle easy taps on the hammer if you go slow you will see it form nicely. If you get impatient and go for big hits you may put in sharp bends you don't want. A vise is good for bending too, but you will find the bends not as clean. If you can find a piece of pipe or some thing solid enough in about the same curve pattern just tap away and don't be afraid to just use your hands at times to just squeeze it the right way. Hope that helps.

Paul

Cheers for that Paul, I discovered tonight it's really easy just to do it by hand. I made myself up something to bend around tonight which I'll post up shortly in my rebuild thread.

It's not 100% sturdy so I made some modifications so hopefully it'll last through the job, but I potentially got my first bit bent up...

[john82q]

the one with the most toys wins, right?

Pete,
vice hammer, some muscle and something solid slightly smaller that the desired radius, youll be right. (More satisfying that way)

But if you get stuck, or want a tight curve, full circles, s bends,or precis degrees sing out, I have a couple of metal bending machines (grooved rollers , etc) you can use.

Also a dab hand with the stick welder, if you want a quick lesson.

John

[pete]

Pete,
vice hammer, some muscle and something solid slightly smaller that the desired radius, youll be right. (More satisfying that way)

But if you get stuck, or want a tight curve, full circles, s bends,or precis degrees sing out, I have a couple of metal bending machines (grooved rollers , etc) you can use.

Also a dab hand with the stick welder, if you want a quick lesson.

John

Haha like the subject John, too true!

I think my ex-cat pole solution will work ok for the bending, but the welding... well we'll see... may need a lesson or three if it's too much different to soldering on a bigger scale...

[mike-s]

What's it made from? aluminium? you can just aluminium braze it! that's easily done.

[pete]

Nah 6.3mm galvanised steel so should in theory be easy to weld... as long as I can learn to do it effectively enough