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  1. #1

    Default Air over hydraulic tubing bender build

    Ok first Off I started with a set of plans from www.gottrikes.com I'm Building the B version.

    1st pic) This is me mooching my neighbors mill LOL self portrait and all these with my Phone.
    Attachment 1487

    2) the is how the mill started the day off dusty and clean , Muahahah just wait LOL
    Attachment 1488

    3) Decided to start with the Draw bar construction and the milling and drilling on the 2 18" x 3" x1/4" arms.
    Attachment 1489

    4) After cutting them to a tad over 18" setting up to skim them down to 18 on the button.
    Attachment 1490

    5) After Dye chem and some measuring and scribing. I start my Pilot holes, I'm using 2 other drill bits of the same size butt end in the holes to keep the parts aligned while drilling that way I only have to clamp on one side.
    Attachment 1491

    6) I enlarged the smaller holes from the previous photo to all 1/2", and still using the butt end of one of the 1/2" drills I am boring 7/8" holes now. Some remain 7/8 and one gets enlarged to 1-3/8"
    Attachment 1492

    7) Final Product two exactly 18" Long, 3" x 1/4" with holes that match exactly because I drilled them stacked and used aligning pins in the holes during every drilling and milling process.
    Attachment 1493

    That's about it for now I got a bunch of 2" square stock to cut, when I get to more technical or assembly/welding I will continue.... Stay tuned
    Last edited by aaxiss; 04-06-2011 at 05:13 AM. Reason: fix typo
    Don

    MTS 200 workhorse
    PowerTig 250EX <---sweet
    80 amp HF inverter arc welder
    Lincoln Buzzbox
    Rotobrute AC-35 Mag Drill
    Milwaukee mag drill
    HF Heavy Duty 16 Speed Bench Drill Press (Custom made Adjustable Height stand)

    I gotta find more junk to sell on EBaY ... Must Buy a Plasma Cutter and a Mig Welder


    Fullerton, Ca
    USA

  2. #2

    Default

    nice! I'll definetly be keeping track of this build.


    what dies are you using? or building?
    I'd like to think I'm the guy they are talkin about when they say, "he could F%^& up a cannon ball in a plowed field."
    .................. /...\
    ..............-...|.....|
    ...*.......-'. \..\__/
    ....\.-'.........\
    ... /......... _/
    ...|......... /"
    ...|.... /_\'
    ....\....\_/
    ......""""

  3. #3

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    will be using the pro tool 105 dies. 1" or 7/8 " die set to make a tube frame for a 4 wheel e-bike except mine is gonna do 60 mph and get there in under 3 sec. stay tuned for that one later this summer

    I could make my own dies if the mill was cnc. then have them hardened. easier to just buy them as you need the different sizes.
    Don

    MTS 200 workhorse
    PowerTig 250EX <---sweet
    80 amp HF inverter arc welder
    Lincoln Buzzbox
    Rotobrute AC-35 Mag Drill
    Milwaukee mag drill
    HF Heavy Duty 16 Speed Bench Drill Press (Custom made Adjustable Height stand)

    I gotta find more junk to sell on EBaY ... Must Buy a Plasma Cutter and a Mig Welder


    Fullerton, Ca
    USA

  4. #4

    Default

    Don, what sort of ultimate tonnage pressure will this air over hydraulic setup develop?

    Glen
    Everlast PP256
    Everlast Imig 200
    Everlast Power Ultra 205
    P&H 400 amp A.C.
    Miller 230 amp with Onan power

  5. #5

    Default

    By e-bike you mean electric? That will be awesome! you can get massive hp and acceleration out of those electric motors.
    I'd like to think I'm the guy they are talkin about when they say, "he could F%^& up a cannon ball in a plowed field."
    .................. /...\
    ..............-...|.....|
    ...*.......-'. \..\__/
    ....\.-'.........\
    ... /......... _/
    ...|......... /"
    ...|.... /_\'
    ....\....\_/
    ......""""

  6. #6

    Default

    Glen: I don't know the exact math but it's an 8 ton 18-3/4" travel ram working the end of an 18 draw bar. here are the specs for the dies it uses and the bender will handle all of them and the pipe dies too
    http://www.pro-tools.com/105tdies.htm

    Scratchstart: I will be using a parallel - series configuration or lithium Iron Phosphate batteries. the stack of Lithium cells on the left of the two car batteries will produce 47v @ 20ah for 1/3 the weight of the two car batteries pictured next to them for 1/3 the weight. ( picture one ), through a 500 amp rated solenoid and controller to a series excited DC motor 62hp and 118 ft lbs of torque ( Picture two )


    oh I forgot to add, the vehicle will have a total weight with me in it of 620 lbs approx and should be capable of 0-60 in 1.9 secs with some fatty rear tires and a wheelie bar on the back top speed should be around 60-70 mph but I am gearing it way down for the torque and acceleration, ( geared up well over 100.... too fast ). I wanna see the look on some of these guys riding the Big sport bikes when they get smoked throught the lights by a guy in a wheelchair / electric bike LOL If I get caught buy the cops I am gonna try and play the disabled card if that doesn't work I'll have to get it registered as a golf cart type vehicle. I am adding a hidden limiter switch which I will be able to program into the controller so It will only do 18 mph ( Legal electric wheelchair speed )

    width will be 49" and wheelbase will be 54" I will have a roll hoop but not a full cage. also one side will have welded side impact protection and the side I transfer in from my wheelchair will have swing up side impact bars held in place by mil-spec titanium pins to facilitate entry for me to swing my legs in. It will be a while before I can afford to purchase the batteries and motor but once the bender is done I will probably make a couple more to sell to raise funds for the fun stuff .. I need my Powertig 250 soon

    Attachment 1532Attachment 1531
    Last edited by aaxiss; 04-12-2011 at 02:30 AM. Reason: added more info
    Don

    MTS 200 workhorse
    PowerTig 250EX <---sweet
    80 amp HF inverter arc welder
    Lincoln Buzzbox
    Rotobrute AC-35 Mag Drill
    Milwaukee mag drill
    HF Heavy Duty 16 Speed Bench Drill Press (Custom made Adjustable Height stand)

    I gotta find more junk to sell on EBaY ... Must Buy a Plasma Cutter and a Mig Welder


    Fullerton, Ca
    USA

  7. #7

    Default

    I've been debating building vs buying a tubing bender. Will a drill press work or do you have to use a mill? Will you save any money building your own? I have the plans that pro tools will email you for free, I'm just not sure I will save any money considering the price of the dies. I can't get the idea of building my own out of my head.

    What is the type and size of your neighbors mill?
    Lincoln Eagle Engine Drive
    Everlast MTS 250
    Everlast Power Tig 225lx
    HTP Mig 2400
    Everlast Power Plasma 60C --> Just need to finish my CNC Plasma Table!
    Miller Spectrum 375 Extreme Plasma cutter
    Victor cutting torch
    HF 20 Ton Shop Press
    HF 4x6 Band Saw
    HF Air Compressor
    Northern Tool Drill Press


    www.murphywelding.com

  8. #8

    Default

    Quote Originally Posted by aaxiss View Post
    oh I forgot to add, the vehicle will have a total weight with me in it of 620 lbs approx and should be capable of 0-60 in 1.9 secs with some fatty rear tires and a wheelie bar on the back top speed should be around 60-70 mph but I am gearing it way down for the torque and acceleration, ( geared up well over 100.... too fast ). I wanna see the look on some of these guys riding the Big sport bikes when they get smoked throught the lights by a guy in a wheelchair / electric bike LOL If I get caught buy the cops I am gonna try and play the disabled card if that doesn't work I'll have to get it registered as a golf cart type vehicle. I am adding a hidden limiter switch which I will be able to program into the controller so It will only do 18 mph ( Legal electric wheelchair speed )

    Attachment 1532Attachment 1531
    HOLY FF!!!! 0-60 in <2 seconds!!! YOU ARE MAD. There must be video shot when you complete this, I want to see it.

    What do you expect the total build cost to be? When do you anticipate it being completed?
    Last edited by zoama; 05-28-2012 at 02:52 AM. Reason: fixed the quote code
    Build it, wheel it, break it, fix it, and repeat!!!!!!!

    Tools:
    Everlast SuperCut 50 Plasma
    Century 200 Mig welder
    JD2 Model 32 Tube Bender

    Toys:
    1995 Ranger 2wd regular cab - 5.0HO Conversion - Street Machine
    1993 Ranger SuperCab - 466 BBF - Extreme offroad
    1985 F250 Regular Cab 4x4 - 460 BBF - Towing Beast

  9. #9

    Default

    Sean Murphy: I will be purchasing ( Read my " Pops " ) a drill press in a few days I will be building 2 of these simultaneously ( a friend wants one and I need the 400 over cost he's willing to pay ) I will be doing the other one with a drill press but I think I am going to have to go in much smaller steps on the bit sizes than I did in the mill but from what I have done already I have no doubts just make sure the drill press your using is capable of a spindle speed of about 250 rpm or even lower for the 1 3/8" cut you don't want the bit chattering and you don't want the chips coming off the bit any color but the shiny steel color their made of or you cutting too fast. A light amber color is acceptable if your running coolant over the bit while cutting but I just used wd-40 and went at it fairly slow although I did stack the pieces. Not necessary if you take your time and lay out each piece exactly and center punch you converging measurements and start with a small drill that won't dance out of the punch.

    Deranged : I will have lots of video when it's done and expect the total cost to be around $3500 but would be lower using 4 Optima yellow tops but I would gain over 100 lbs and save only $350 . I am willing to wait and do it the way I want. If I can sell some benders it may get done really soon. should have some cad drawings soon . My RX7 Turbo Torsen Diff cam in today though so I can start on that. it's removed from the housing and I will weld up the openings and add 2 1/2" bungs 180deg of each other and fill it with 90 wt to help is be more posi than limited slip. only one is necessary but it's easier to balance the diff that way with less machining after I weld it closed. will ditch the ring gear on it and bolt a 89 tooth gear on there with a heavy duty gear protector under it cause it will dip 2" below the frame and you think I wont be getting any air with 10" travel front and rear LOL I'm going to start a build on that soon so I don't want to get too far off track on this thread so that's it for now on the Hyper-bike.
    Don

    MTS 200 workhorse
    PowerTig 250EX <---sweet
    80 amp HF inverter arc welder
    Lincoln Buzzbox
    Rotobrute AC-35 Mag Drill
    Milwaukee mag drill
    HF Heavy Duty 16 Speed Bench Drill Press (Custom made Adjustable Height stand)

    I gotta find more junk to sell on EBaY ... Must Buy a Plasma Cutter and a Mig Welder


    Fullerton, Ca
    USA

  10. #10
    Join Date
    Apr 2011
    Location
    Sasktachewan, Canada
    Posts
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    Default

    Axxiss

    Nice workmanship. I checked out that web link to the power bender. I have a hand one for flat or small cold rolled stock. And a hydraylic one that was on sale at Princess Auto but no really happy with it. I was really impressed by that video and it looks like a fun project. How much were the plans?
    Attitude Determines Altitude

  11. #11

    Default

    ok, I can see one thing your missing... a cool sound, you know how the storm trooper bikes sounded on the starwars movies..... you NEED THAT SOUND!

    looking forward to seeing more of this build.... and the tube bender too.
    I'd like to think I'm the guy they are talkin about when they say, "he could F%^& up a cannon ball in a plowed field."
    .................. /...\
    ..............-...|.....|
    ...*.......-'. \..\__/
    ....\.-'.........\
    ... /......... _/
    ...|......... /"
    ...|.... /_\'
    ....\....\_/
    ......""""

  12. Default

    looks good so far wish i had 1 myself
    everlast i-mig 200
    96 gmc extended cab truck 350 rwhp daily driven for 289,000 miles
    88 jeep cherokee custom built by me for me for well everything.someday it'll be finished
    4.6L stroker,dana 44 front, 14 bolt rear, 35"xterrains,soon to come 231/205 doubler

  13. #13

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    My parents are going on vacation tomorrow so my new welder is going to sit at the neighbors house till Sunday, Besides I'm Kinda broke at this time I don't even have enough to go get an argon bottle. Got plenty of 6011 rod for my stick welder so I may start on the frame of the bender on Monday when my parents get back. I have the bushings and pins from McMaster carr and Just about all I need but the dies atm. So I can continue on this project and my Tig cooler build will continue when I can buy the bypass valve and a 150cf argon bottle to weld up the tank and the enclosure.
    Don

    MTS 200 workhorse
    PowerTig 250EX <---sweet
    80 amp HF inverter arc welder
    Lincoln Buzzbox
    Rotobrute AC-35 Mag Drill
    Milwaukee mag drill
    HF Heavy Duty 16 Speed Bench Drill Press (Custom made Adjustable Height stand)

    I gotta find more junk to sell on EBaY ... Must Buy a Plasma Cutter and a Mig Welder


    Fullerton, Ca
    USA

  14. #14

    Default

    OK not much progress but for those of you that don't have access to big fancy mills or giant floor standing 2 hp drill presses. I am going to show what I can accomplish and how accurate you can be if you take your time and measure and mark properly. first think to check is the base of the drill, is it on a level surface?. now you check the chuck to base accuracy. I use a 1/2 piece of drill stock and a digital angle gauge but a level would work fine here too. now bring up your adjustable work platform and check that it's 90 deg to the bit on both the x and y axis. I all that checks your good to go.

    Now drilling with a small drill like this presents problems because of spindle speed and the lack of speeds under 650 rpm . at least on mine. so when you start the pilot holes I am using a harbor freight step bit starting at 1/8 and going to around 1/4" where I will switch to a bit that will create the bore all the way through and increase from there in about 1/4 increments. we shall see how this goes. here are some pictures. the HF step bit had no problems popping 1/4" holes in the 1/4 wall 2" TUBING.

    Here are some pictures, more tomorrow. in the last picture you can see my layout lines and my center punches, start the small holes in these and progress up in size slowly

    Attachment 1604Attachment 1603Attachment 1605
    Last edited by aaxiss; 04-13-2011 at 05:04 AM.
    Don

    MTS 200 workhorse
    PowerTig 250EX <---sweet
    80 amp HF inverter arc welder
    Lincoln Buzzbox
    Rotobrute AC-35 Mag Drill
    Milwaukee mag drill
    HF Heavy Duty 16 Speed Bench Drill Press (Custom made Adjustable Height stand)

    I gotta find more junk to sell on EBaY ... Must Buy a Plasma Cutter and a Mig Welder


    Fullerton, Ca
    USA

  15. #15

    Default

    I have had good luck with those bits, I get them on sale, and keep the oiled. My old drill press was too fast and would wallow the holes, using the step bits kept the holes from wallowing out. My new drill press gets down to 210rpm, I'm trying to find a good project to break it in!
    Lincoln Eagle Engine Drive
    Everlast MTS 250
    Everlast Power Tig 225lx
    HTP Mig 2400
    Everlast Power Plasma 60C --> Just need to finish my CNC Plasma Table!
    Miller Spectrum 375 Extreme Plasma cutter
    Victor cutting torch
    HF 20 Ton Shop Press
    HF 4x6 Band Saw
    HF Air Compressor
    Northern Tool Drill Press


    www.murphywelding.com

  16. #16

    Default

    I have built several of the ones from gottrikes now and thy work great, finding something small i do differently each time. I have sold the last 2 i have made for myself thinking i wouldn't need it again, this one is going to be a keeper lol. I started on the base Tuesday but got wrangled into building some kitchen cabinets for my mom and dad, the cherry laminate came in yesterday and I'll laminate the cabinets build the drawers from 7 layer cabinet grade ply and the fronts from solid cherry. Also doing leaded glass panels for the doors. Easier and cheaper.

    But i digress, on my strong hand welding table clone thread i posted pics of the base construction, should have the entire frame done by next weekend and fully completed in 2 weeks if i work while glue and strain etc dry.

    It's funny being the only seriously mechanically inclined person in my whole family, I've made my entire living from family members for the last 4 months of work. And my abilities are somewhat limited by my situation. They're able bodied but and lazy as he'll , I'm in a wheel chair and they all turn to me when they want something. I tell them out says about more about them than it does me haha

    Sent from my Nexus 7 using Tapatalk 2
    Don

    MTS 200 workhorse
    PowerTig 250EX <---sweet
    80 amp HF inverter arc welder
    Lincoln Buzzbox
    Rotobrute AC-35 Mag Drill
    Milwaukee mag drill
    HF Heavy Duty 16 Speed Bench Drill Press (Custom made Adjustable Height stand)

    I gotta find more junk to sell on EBaY ... Must Buy a Plasma Cutter and a Mig Welder


    Fullerton, Ca
    USA

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