We all have old projects which maybe didn’t quite deliver knocking about, sometimes they gather dust for years. They have a use though, in that when you *really* need that part you can lift it from that forgotten project. That’s what [Mustie1] did with a forgotten electric bicycle project, he took its motor and used it to automate his bead roller.
A bead roller is a tool used in the world of automotive bodywork to press a bead — a continuous depression — into a piece of sheet metal. The inexpensive roller he had fitted in a bench vice, and was operated by means of a handle. Unfortunately the size of the tool meant that it was difficult to operate at the same time as rolling a precise bead, so improvement was required.
He first considered using a cordless drill, but then remembered the electric bicycle project. Its geared motor had come from an electric wheelchair and certainly possessed the right speed, but he needed a suitable sprocket. This was supplied from a scrap engine-assisted bicycle that he’d acquired, and proved to be perfect for the job. The final automated roller used the trigger controller from a cordless drill mounted in a foot switch, and the roller mounted on a stand repurposed from a piece of gym equipment. The result is a useful, and above all controllable, tool that can run a perfect bead in any shape desired on a piece of sheet metal.
Surprisingly this is the first bead roller we’ve featured here, but sheet metal work is a constant in hardware hacker projects. Read our guide to sheet metal bending, for a start.
Thanks [Cliff Miller] for the tip.
9 thoughts on “Electrification Of A Cheap Bead Roller”
Done good job. This was nice using bead roller on buy cycle.
Mustie made HackaDay? This may be the greatest day in the life of the Internet! That man can fix, start, or hack just about anything.
Amen! Search YouTube for Mustie1.
I love his rocker cover foot switch
Mustie’s the reason I got into small engine repair and welding. He has also contributed to my already present desire to find an old air-cooled VW engine and bring it back to life.
This is pretty awesome, thanks for sharing!
Such a reasonable hack!
How on earth you can even think man!!
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