DIY Roll Bender Keeps It Simple And Sturdy

If you’ve ever tried to bend a metal pipe or bar over your knee, you’ll know that even lightweight stock requires quite a bit of force. And the force needs to be properly directed, lest the smooth bend you seek become a kink or a crease. When your hands and knees no longer fill the bill, try [MakeItExtreme]’s sturdy and simple roll bender.

As we watched the video below, we had a little déjà vu — hadn’t the [MakeItExtreme] crew built a roll bender for their shop before? Turns out they had, but in reviewing that video, we can see why they gave it a second shot. This build is a model of simplicity compared to the previous. With a frame fabricated from just a few pieces of steel I-beam, this version is far more approachable than its big brother and just about as capable. The three forming rollers ride in stout pillow blocks and can be repositioned for different bending radii. A 2-ton hydraulic bottle jack provides the force needed to direct the stock through the rollers, which are manually powered. In a nice touch, the incomplete tool was used to create the rim of the large-diameter handwheel for the drive roller.

The tools keep piling up at [MakeItExtreme]’s open air workshop — we even get a glimpse of their heavy-lift electromagnet that we recently featured. As always, we love the fit and finish on these builds, and watching the time-lapse videos is like a condensed class in metalworking.

Continue reading “DIY Roll Bender Keeps It Simple And Sturdy”

Vise Reborn As A Roll Bender

Have you ever tried bending a metal rod into a consistent curve? Maybe you bent it over your knee or broke out a bucket or something. Doing it by hand never really gets the arc perfect. Handyman [Joe] found himself needing to bend a bunch of 1/4″ metal rod into various diameter rings. He didn’t have any tools to bend or roll metal and instead of fretting about it, he put on his ingenuity hat and built a perfect tool for the job.

That perfect tool is called a Roll Bender and it uses 3 rollers to bend metal into an arc of consistent radius. The straight piece of metal is passed by the rollers many times. The distance between the rollers is continually adjusted to reduce the radius of the arc of the metal until it reaches the correct size.

[Joe] started out with an old drill press vise. A piece of plate steel was welded to the  stationary vise jaw to provide a platform for a grooved pulley to be mounted. On the clamping jaw, a piece of angle iron was attached to support two very large bearings. The metal rod is clamped between the two bearings and the grooved pulley. A key made from a socket and some scrap metal as a handle allow the user to rotate the pulley by hand while the distance between the rollers is adjusted by the vise’s crank. Doing this moves the rod back and forth between all 3 rollers to gradually mold the once-straight rod into a full ring.

We’ve always been fond of machines that do the bending for you. Even if they haven’t been invented yet.