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Project "Bend It" (Modding tool Build Log)

post #1 of 12
Thread Starter 
Hiya guys, I am on a mission to build a bender sorta like a Sheet Metal Brake but it has to be fully adjustable to also bend Aluminum,Polycarbonate,Sheet metal and any other materials that may need bending.I only get 1 day to actually borrow a Machine shop to get whatever i can get done there done. (Actually will be there 2 days but 1 day is for refreshing me on use of the Bridgeport,Lathe and other Equipment for safety reasons of course) I haven't run a Bridgeport or any equipment like that in roughly 10 years so i will be doing the best i can in that time frame.

Goals of the tool:
Must be able to bend Sheet metal all the way back down upon itself. (To make a lip.Like on a case doors edge etc.)
Must be Fully adjustable.
Must be able to Bend Metals and Plastics (Some plastics will need help of a heat gun to bend)
Build it as Cheap as possible.
Must be able to fit any length of material with a width of at least 2 Feet.
Must be rather Small but still strong.

Materials used and Prices:
All the metal Was Scrap we found laying around (Free)
Welding Rods (I had them but paid $3.99 for the Box)
Dupli-Color Filler Primer High Build Formula $6.99
Rustoleum Professional High performance Safety Blue Enamel (Basically Industrial Paint) $9.99
Hardware Bolts,Nuts and washers. (Used what i had laying around)
(Will update list if other stuff is needed)
   
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post #2 of 12
Thread Starter 
Ok Lets begin (Sorry about the horrible Photo's)

Adjustable and removable Side Plates that also act as Part of the Hinge:
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Here is the Main body of the Bender.Basically used the Band Saw to cut the blocks on the side then the Bridgeport to make sure the matched perfect.Also used the drill press to drill the holes and Tap the holes with a special attachment. (Sorry dont know the name of the attachment but it Taps the threads down when you push the Drill press down and it reverses when you pull up to make perfect threads easily) Next welded the plates together and cut notches for the Hinge pins to fit. Used the Bridgeport to notch it.

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Here is the front Plate before cleaning anything up its in its raw state.The welding is strong but not beautiful.I wasnt to concerned of this because i would be cleaning it up and its just a tool.Work done was cut the Angle iron with the Bridgeport to make the small edge.Used the Lathe to hollow partly out the Handle holders and drilled a hole in the end just so air could escape when putting the handles in and out.Also Cut 2 Pins from solid round stock. Added 2 nuts to the handle holders drilled and tapped through them to hold the handles in place.Welded everything up.

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Here is the actual clamp to hold down the materiel being bent.It can be spaced up and down or forward and back depending on what i need it to do.Or can be used to get past 90 degrees and then removed to fold all the way down on itself.Lol this started as an old bed frame.The side pieces were just cut off pieces of angle iron welded on and then grooved with the Bridgeport.This is the top view.

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And to make it stronger this is far from pretty but it adds tons of strength.We added a round hollow pole in the middle with thick walls to avoid any flex while bending.Remember this is all in very Raw state at the moment;

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Last Part was rather simple.We found some nice strong hardened round stock that we cut into handles and then used a belt sander to make them a nice snug fit.This stuff was hell to cut.It almost killed the Band saw blade in a second so i immediately switched to a chop saw with a metal cutting blade sorta like you use on a Dremel but very large.

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Next to make sure the surface was Flat it went into the Bridgeport again together to make a nice level surface.:

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Here is what i have so far in rough state and it seems to do everything Expected of it.Beside's the fact its ugly right now everything is perfect.

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And here it is bending a Piece of Cold Polycarbonate roughly 40 degrees Fahrenheit with no heat at all.

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And here are just Random pictures of that awesome day in the shop and some other shots of it being built:

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Much more to come Please check back to see it in action and looking pretty.The rest of the work i have to do at my house so there may be some modifications made to the design along with painting etc. I had to build what i could in the 1 day use of the shop i had so i came up with a quick design from what scraps we had and whipped it together to the point its at now.

So for the time and Cash spent so far and how it actually performs so far i consider it a total Success! So far at least smile.gif

More Updates Soon!
   
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post #3 of 12
Thread Starter 
More updates Today ! Just trying to drink my coffee and get Motivated and then i will be adding the new Pictures.

Keep watching because it looks like junk right now but the thing Honestly is an incredible tool for Modding.

Here is another Photo or 2 showing how tight of a radius it can do when adjusted.

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post #4 of 12
This is cool! looking forward to seeing what else you have in mind for the project/ projects to come from this .
My System
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post #5 of 12
Looks great! thumb.gif
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post #6 of 12
Wow that thing looks awesome! I'm so jelly about your dad's shop caus it's just a modder's dream biggrin.gif
 
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post #7 of 12
Thread Starter 
Quote:
Originally Posted by glinux View Post

Wow that thing looks awesome! I'm so jelly about your dad's shop caus it's just a modder's dream biggrin.gif

Lol i wish it was my dads Shop. That is just a shop a guy let me use for 2 days.Day 1 was Training on the equipment and day 2 i had to build whatever i could .fast as i could.So i Made the bender best i could with the time frame i had and the scraps we had laying around.


Here are some new updates.I welded it to a stand that was going to be an oven for Powder coating but now is my new bender stand.Besides welding it with my little welder i just sanded everything down and painted some parts.I cant paint all of it because the paint is tough but slow drying.You can see my actual tiny shop in the photos below.

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My Pitiful Little Shop: But it does have most everything i need.There are other modding tools in the yard covered and i am currently working on a little shop in my basement also.

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2 OCZ Vertex 3's Striped Raid 0 2Tb WD Black Asus Dual Layer Burner Custom Loop 
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Windows 7 Ultimate 64 bit Hanspree 23" 1080p Monitor Hdmi and 55" Toshiba... Microsoft Sidewinder x6 Gming Keyboard Painted and Fully Sleeved Cougar 1050watt 
CaseMouseMouse PadAudio
NZXT Phantom White (Chrome Yellow Now! ) Cyborg Rat 5 Cheapo organomic one. Bose Campanion 3 
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i5 2500k @ 5ghz AsRock Fatal1ty P67 Professional Powercolor Hd6970 Corsair Dominator c9 2133mhz Ram kit 
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OCZ VERTEX II WD Black Asus Dual Layer Dvd Burner w/Lightscribe EK HD6970 water block (Nickel) 
CoolingCoolingCoolingCooling
EK Gpu Ram Plate EK Dominator Ram cooler Rasa RS360 KIT Magicool Extreme Dual 120mm Radiator  
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3 Bitspower Ratory 1/2IDx3/4OD Compression Fitt... 7 Bitspower Compression fittings High Quality anti kink Primochill 1/2x3/4 Tubing 9 NZXT fANS (8 120'S and 1 140) 
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Microsoft Windows 7 Ultimate 64 bit Handspree 23" 1080p Hdmi and 55" Toshiba Led (H... Microsoft wireless keyboard 3000 v2 Modded Cougar SX850 (Painted and Sleeved) 
CaseMouseMouse PadAudio
Modded NZXT Phantom Basic Microsoft Optical mouse for now. Black Gel Orgenomic Mousepad (not sure brand na... 2.1 Klipsche System (was top of the line 4 year... 
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Antec Veris Premier Nzxt Sleeved Led Kits (White) 
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Requiem Revamp
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Intel I7-2700K AsRock Fatal1ty Professional Z68 Gen 3 Powercolor HD6970  Powercolor HD6970 
RAMHard DriveCoolingOS
4 Gig Corsair Dominators  2 Plextor 128Gig M3 Pro Series SSD's Raid 0 ekwb Dual Loop Windows 7 Ultimate 64 bit 
MonitorKeyboardPowerCase
25" HP 2511x Microsoft Sidewinder x6 1000w NZXT Hale90 PSU NZXT Switch 810 
MouseMouse PadAudioOther
Rat 5 Razer Vespula Bose  other Parts from ekwb / NZXT / Primochill / Mnp... 
CPUMotherboardGraphicsRAM
Intel i7 2700k  AsRock Fatal1ty Professional Z68 Gen3 PowerColor Hd6970 2gig (Reference) Corsair Dominator Gt's 1.5 volt 
Hard DriveHard DriveOptical DriveCooling
2 OCZ Vertex 3's Striped Raid 0 2Tb WD Black Asus Dual Layer Burner Custom Loop 
OSMonitorKeyboardPower
Windows 7 Ultimate 64 bit Hanspree 23" 1080p Monitor Hdmi and 55" Toshiba... Microsoft Sidewinder x6 Gming Keyboard Painted and Fully Sleeved Cougar 1050watt 
CaseMouseMouse PadAudio
NZXT Phantom White (Chrome Yellow Now! ) Cyborg Rat 5 Cheapo organomic one. Bose Campanion 3 
CPUMotherboardGraphicsRAM
i5 2500k @ 5ghz AsRock Fatal1ty P67 Professional Powercolor Hd6970 Corsair Dominator c9 2133mhz Ram kit 
Hard DriveHard DriveOptical DriveCooling
OCZ VERTEX II WD Black Asus Dual Layer Dvd Burner w/Lightscribe EK HD6970 water block (Nickel) 
CoolingCoolingCoolingCooling
EK Gpu Ram Plate EK Dominator Ram cooler Rasa RS360 KIT Magicool Extreme Dual 120mm Radiator  
CoolingCoolingCoolingCooling
3 Bitspower Ratory 1/2IDx3/4OD Compression Fitt... 7 Bitspower Compression fittings High Quality anti kink Primochill 1/2x3/4 Tubing 9 NZXT fANS (8 120'S and 1 140) 
OSMonitorKeyboardPower
Microsoft Windows 7 Ultimate 64 bit Handspree 23" 1080p Hdmi and 55" Toshiba Led (H... Microsoft wireless keyboard 3000 v2 Modded Cougar SX850 (Painted and Sleeved) 
CaseMouseMouse PadAudio
Modded NZXT Phantom Basic Microsoft Optical mouse for now. Black Gel Orgenomic Mousepad (not sure brand na... 2.1 Klipsche System (was top of the line 4 year... 
OtherOther
Antec Veris Premier Nzxt Sleeved Led Kits (White) 
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post #8 of 12

Now that I see how you did it, I think I might be able to make one toothumb.gif Good job! I really did not realise how simple these could be made.

    
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Western Digital Caviar Black 750GB SATA 6GBPS Antec Kuhler 920 H20 CPU Liquid Cooler Evercool Aluminum 120MM Blue LED case fan 3x NZXT 120MM Blue LED case fan 
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Windows 7 Ultimate x64 SP1 HP 19" 16X10 w1907 Rebranded HP Bluebird PS/2 Multimedia Slim keyboard  Antec Truepower New 650Watt 
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Western Digital Caviar Black 750GB SATA 6GBPS Antec Kuhler 920 H20 CPU Liquid Cooler Evercool Aluminum 120MM Blue LED case fan 3x NZXT 120MM Blue LED case fan 
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Windows 7 Ultimate x64 SP1 HP 19" 16X10 w1907 Rebranded HP Bluebird PS/2 Multimedia Slim keyboard  Antec Truepower New 650Watt 
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post #9 of 12
Thread Starter 
you can make a really simple one with just some angle iron and hinges.I made a simple on first because i needed it badly for something.The when i realized how great of a tool they are a made the heavy duty fully adjustable one.The first one i didn't need any machine equipment or anything .I build it in my back yard with some bed frame rails.Its is really ugly but it also works.I use it still because it will do a tighter radius for smaller stuff.

Here is a picture of the first one i whipped together really fast. Warning its Ugly:But it worked fine for sheet metal and plastics.I just had to use C clamps or clamps like you see on there now.But that one took like an hour to through together .

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Requiem Revamp
(26 items)
 
CPUMotherboardGraphicsGraphics
Intel I7-2700K AsRock Fatal1ty Professional Z68 Gen 3 Powercolor HD6970  Powercolor HD6970 
RAMHard DriveCoolingOS
4 Gig Corsair Dominators  2 Plextor 128Gig M3 Pro Series SSD's Raid 0 ekwb Dual Loop Windows 7 Ultimate 64 bit 
MonitorKeyboardPowerCase
25" HP 2511x Microsoft Sidewinder x6 1000w NZXT Hale90 PSU NZXT Switch 810 
MouseMouse PadAudioOther
Rat 5 Razer Vespula Bose  other Parts from ekwb / NZXT / Primochill / Mnp... 
CPUMotherboardGraphicsRAM
Intel i7 2700k  AsRock Fatal1ty Professional Z68 Gen3 PowerColor Hd6970 2gig (Reference) Corsair Dominator Gt's 1.5 volt 
Hard DriveHard DriveOptical DriveCooling
2 OCZ Vertex 3's Striped Raid 0 2Tb WD Black Asus Dual Layer Burner Custom Loop 
OSMonitorKeyboardPower
Windows 7 Ultimate 64 bit Hanspree 23" 1080p Monitor Hdmi and 55" Toshiba... Microsoft Sidewinder x6 Gming Keyboard Painted and Fully Sleeved Cougar 1050watt 
CaseMouseMouse PadAudio
NZXT Phantom White (Chrome Yellow Now! ) Cyborg Rat 5 Cheapo organomic one. Bose Campanion 3 
CPUMotherboardGraphicsRAM
i5 2500k @ 5ghz AsRock Fatal1ty P67 Professional Powercolor Hd6970 Corsair Dominator c9 2133mhz Ram kit 
Hard DriveHard DriveOptical DriveCooling
OCZ VERTEX II WD Black Asus Dual Layer Dvd Burner w/Lightscribe EK HD6970 water block (Nickel) 
CoolingCoolingCoolingCooling
EK Gpu Ram Plate EK Dominator Ram cooler Rasa RS360 KIT Magicool Extreme Dual 120mm Radiator  
CoolingCoolingCoolingCooling
3 Bitspower Ratory 1/2IDx3/4OD Compression Fitt... 7 Bitspower Compression fittings High Quality anti kink Primochill 1/2x3/4 Tubing 9 NZXT fANS (8 120'S and 1 140) 
OSMonitorKeyboardPower
Microsoft Windows 7 Ultimate 64 bit Handspree 23" 1080p Hdmi and 55" Toshiba Led (H... Microsoft wireless keyboard 3000 v2 Modded Cougar SX850 (Painted and Sleeved) 
CaseMouseMouse PadAudio
Modded NZXT Phantom Basic Microsoft Optical mouse for now. Black Gel Orgenomic Mousepad (not sure brand na... 2.1 Klipsche System (was top of the line 4 year... 
OtherOther
Antec Veris Premier Nzxt Sleeved Led Kits (White) 
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Requiem Revamp
(26 items)
 
CPUMotherboardGraphicsGraphics
Intel I7-2700K AsRock Fatal1ty Professional Z68 Gen 3 Powercolor HD6970  Powercolor HD6970 
RAMHard DriveCoolingOS
4 Gig Corsair Dominators  2 Plextor 128Gig M3 Pro Series SSD's Raid 0 ekwb Dual Loop Windows 7 Ultimate 64 bit 
MonitorKeyboardPowerCase
25" HP 2511x Microsoft Sidewinder x6 1000w NZXT Hale90 PSU NZXT Switch 810 
MouseMouse PadAudioOther
Rat 5 Razer Vespula Bose  other Parts from ekwb / NZXT / Primochill / Mnp... 
CPUMotherboardGraphicsRAM
Intel i7 2700k  AsRock Fatal1ty Professional Z68 Gen3 PowerColor Hd6970 2gig (Reference) Corsair Dominator Gt's 1.5 volt 
Hard DriveHard DriveOptical DriveCooling
2 OCZ Vertex 3's Striped Raid 0 2Tb WD Black Asus Dual Layer Burner Custom Loop 
OSMonitorKeyboardPower
Windows 7 Ultimate 64 bit Hanspree 23" 1080p Monitor Hdmi and 55" Toshiba... Microsoft Sidewinder x6 Gming Keyboard Painted and Fully Sleeved Cougar 1050watt 
CaseMouseMouse PadAudio
NZXT Phantom White (Chrome Yellow Now! ) Cyborg Rat 5 Cheapo organomic one. Bose Campanion 3 
CPUMotherboardGraphicsRAM
i5 2500k @ 5ghz AsRock Fatal1ty P67 Professional Powercolor Hd6970 Corsair Dominator c9 2133mhz Ram kit 
Hard DriveHard DriveOptical DriveCooling
OCZ VERTEX II WD Black Asus Dual Layer Dvd Burner w/Lightscribe EK HD6970 water block (Nickel) 
CoolingCoolingCoolingCooling
EK Gpu Ram Plate EK Dominator Ram cooler Rasa RS360 KIT Magicool Extreme Dual 120mm Radiator  
CoolingCoolingCoolingCooling
3 Bitspower Ratory 1/2IDx3/4OD Compression Fitt... 7 Bitspower Compression fittings High Quality anti kink Primochill 1/2x3/4 Tubing 9 NZXT fANS (8 120'S and 1 140) 
OSMonitorKeyboardPower
Microsoft Windows 7 Ultimate 64 bit Handspree 23" 1080p Hdmi and 55" Toshiba Led (H... Microsoft wireless keyboard 3000 v2 Modded Cougar SX850 (Painted and Sleeved) 
CaseMouseMouse PadAudio
Modded NZXT Phantom Basic Microsoft Optical mouse for now. Black Gel Orgenomic Mousepad (not sure brand na... 2.1 Klipsche System (was top of the line 4 year... 
OtherOther
Antec Veris Premier Nzxt Sleeved Led Kits (White) 
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post #10 of 12
Thread Starter 
More Updates finally still will do some stuff to it though but its ready to use now:

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Requiem Revamp
(26 items)
 
CPUMotherboardGraphicsGraphics
Intel I7-2700K AsRock Fatal1ty Professional Z68 Gen 3 Powercolor HD6970  Powercolor HD6970 
RAMHard DriveCoolingOS
4 Gig Corsair Dominators  2 Plextor 128Gig M3 Pro Series SSD's Raid 0 ekwb Dual Loop Windows 7 Ultimate 64 bit 
MonitorKeyboardPowerCase
25" HP 2511x Microsoft Sidewinder x6 1000w NZXT Hale90 PSU NZXT Switch 810 
MouseMouse PadAudioOther
Rat 5 Razer Vespula Bose  other Parts from ekwb / NZXT / Primochill / Mnp... 
CPUMotherboardGraphicsRAM
Intel i7 2700k  AsRock Fatal1ty Professional Z68 Gen3 PowerColor Hd6970 2gig (Reference) Corsair Dominator Gt's 1.5 volt 
Hard DriveHard DriveOptical DriveCooling
2 OCZ Vertex 3's Striped Raid 0 2Tb WD Black Asus Dual Layer Burner Custom Loop 
OSMonitorKeyboardPower
Windows 7 Ultimate 64 bit Hanspree 23" 1080p Monitor Hdmi and 55" Toshiba... Microsoft Sidewinder x6 Gming Keyboard Painted and Fully Sleeved Cougar 1050watt 
CaseMouseMouse PadAudio
NZXT Phantom White (Chrome Yellow Now! ) Cyborg Rat 5 Cheapo organomic one. Bose Campanion 3 
CPUMotherboardGraphicsRAM
i5 2500k @ 5ghz AsRock Fatal1ty P67 Professional Powercolor Hd6970 Corsair Dominator c9 2133mhz Ram kit 
Hard DriveHard DriveOptical DriveCooling
OCZ VERTEX II WD Black Asus Dual Layer Dvd Burner w/Lightscribe EK HD6970 water block (Nickel) 
CoolingCoolingCoolingCooling
EK Gpu Ram Plate EK Dominator Ram cooler Rasa RS360 KIT Magicool Extreme Dual 120mm Radiator  
CoolingCoolingCoolingCooling
3 Bitspower Ratory 1/2IDx3/4OD Compression Fitt... 7 Bitspower Compression fittings High Quality anti kink Primochill 1/2x3/4 Tubing 9 NZXT fANS (8 120'S and 1 140) 
OSMonitorKeyboardPower
Microsoft Windows 7 Ultimate 64 bit Handspree 23" 1080p Hdmi and 55" Toshiba Led (H... Microsoft wireless keyboard 3000 v2 Modded Cougar SX850 (Painted and Sleeved) 
CaseMouseMouse PadAudio
Modded NZXT Phantom Basic Microsoft Optical mouse for now. Black Gel Orgenomic Mousepad (not sure brand na... 2.1 Klipsche System (was top of the line 4 year... 
OtherOther
Antec Veris Premier Nzxt Sleeved Led Kits (White) 
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Reply
   
Requiem Revamp
(26 items)
 
CPUMotherboardGraphicsGraphics
Intel I7-2700K AsRock Fatal1ty Professional Z68 Gen 3 Powercolor HD6970  Powercolor HD6970 
RAMHard DriveCoolingOS
4 Gig Corsair Dominators  2 Plextor 128Gig M3 Pro Series SSD's Raid 0 ekwb Dual Loop Windows 7 Ultimate 64 bit 
MonitorKeyboardPowerCase
25" HP 2511x Microsoft Sidewinder x6 1000w NZXT Hale90 PSU NZXT Switch 810 
MouseMouse PadAudioOther
Rat 5 Razer Vespula Bose  other Parts from ekwb / NZXT / Primochill / Mnp... 
CPUMotherboardGraphicsRAM
Intel i7 2700k  AsRock Fatal1ty Professional Z68 Gen3 PowerColor Hd6970 2gig (Reference) Corsair Dominator Gt's 1.5 volt 
Hard DriveHard DriveOptical DriveCooling
2 OCZ Vertex 3's Striped Raid 0 2Tb WD Black Asus Dual Layer Burner Custom Loop 
OSMonitorKeyboardPower
Windows 7 Ultimate 64 bit Hanspree 23" 1080p Monitor Hdmi and 55" Toshiba... Microsoft Sidewinder x6 Gming Keyboard Painted and Fully Sleeved Cougar 1050watt 
CaseMouseMouse PadAudio
NZXT Phantom White (Chrome Yellow Now! ) Cyborg Rat 5 Cheapo organomic one. Bose Campanion 3 
CPUMotherboardGraphicsRAM
i5 2500k @ 5ghz AsRock Fatal1ty P67 Professional Powercolor Hd6970 Corsair Dominator c9 2133mhz Ram kit 
Hard DriveHard DriveOptical DriveCooling
OCZ VERTEX II WD Black Asus Dual Layer Dvd Burner w/Lightscribe EK HD6970 water block (Nickel) 
CoolingCoolingCoolingCooling
EK Gpu Ram Plate EK Dominator Ram cooler Rasa RS360 KIT Magicool Extreme Dual 120mm Radiator  
CoolingCoolingCoolingCooling
3 Bitspower Ratory 1/2IDx3/4OD Compression Fitt... 7 Bitspower Compression fittings High Quality anti kink Primochill 1/2x3/4 Tubing 9 NZXT fANS (8 120'S and 1 140) 
OSMonitorKeyboardPower
Microsoft Windows 7 Ultimate 64 bit Handspree 23" 1080p Hdmi and 55" Toshiba Led (H... Microsoft wireless keyboard 3000 v2 Modded Cougar SX850 (Painted and Sleeved) 
CaseMouseMouse PadAudio
Modded NZXT Phantom Basic Microsoft Optical mouse for now. Black Gel Orgenomic Mousepad (not sure brand na... 2.1 Klipsche System (was top of the line 4 year... 
OtherOther
Antec Veris Premier Nzxt Sleeved Led Kits (White) 
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