Bending tubing for Pannier rack?

Discussion in 'The Garage' started by blaster11, Nov 24, 2013.

  1. blaster11

    blaster11 Still having fun!

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    So I need to build a pannier rack for my Husky as no one makes them. I picked up some hoops but need to figure out how to bend the tubing....any suggestions?
    Here are the hoops I picked up.
    [​IMG]
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  2. DirtDabber

    DirtDabber cultural illiterate

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  3. blaster11

    blaster11 Still having fun!

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    Interesting.
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  4. DirtDabber

    DirtDabber cultural illiterate

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    You can make forms from plywood or even 2x lumber and use a rasp to notch a groove for the tubing to keep it from collapsing. You can experiment with PVC and a heat gun to get your shape then make a wood form based on the PVC.
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  5. blaster11

    blaster11 Still having fun!

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    Not much of a wood worker.
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  6. Bump Stop

    Bump Stop 2 Wheeled Drifter

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    without a hydraulic bender, the only way to do it is with forms and heat. the thinner the wall the easier it kinks.

    my advice would be to find someone in your area with a bender.
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  7. boardrider247

    boardrider247 Weekend Anarchist

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  8. sailah

    sailah Lampin' it

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    I agree on finding someone with a bender, makes it way easier. Check pirate4x4 and ask if you can swap beers for bends.

    You can also buy prebent tubing, cut and weld
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  9. sailah

    sailah Lampin' it

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  10. victor441

    victor441 Long timer

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    Packing the tubes with VERY DRY sand (otherwise a steam explosion is possible :eek1)and heating the tube red hot works well...a lot of work but I enjoy it and don't have a bender so it works for me. FWIW I made a template from coathanger wire so I could get the bends the same on both sides and it worked great on the rack below. There are some good sites and videos on how to do it right and safely...

    [​IMG]
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    TomCrean likes this.
  11. jasonmt

    jasonmt Long timer

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  12. Reklaw59

    Reklaw59 Faster than your Nan.

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    I've just been down that road.
    I made a pipe bender but just couldn't get the bends that I wanted. So I got pissed off and made a flat plate rack from 5mm aluminium, much easier :lol3

    looky here http://www.homemadetools.net/

    There is also a formula/relationship between pipe diameter and bend radius,
    I think its 4 times the pipe diameter = radius of bend.
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  13. blaster11

    blaster11 Still having fun!

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    Thanks for the feedback guys I really appreciate it!. I will look at buying something since I have at least two racks to build or something more simple and use some predone dies. Keep the ideas coming.

    I thought about talking to the Kirkster as he is relatively close but it seemed that he was taking a break from fabrication for others, maybe I will drop him a PM for ideas at a minimum.
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  14. blaster11

    blaster11 Still having fun!

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    Nice job and I like your setup, where did yo get the die?
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  15. TeneRay

    TeneRay Just glassin'

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    Cut a series of notches on the inside of the bend, hand bend, and then fill with welds.
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  16. blaster11

    blaster11 Still having fun!

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  17. kioti

    kioti Cruzinonline

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    I make them.
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  18. sailah

    sailah Lampin' it

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    Having a tubing bender is sweet if you have more than one rack to build id just go ahead and get one. I have the jd squared model three and its awesome.

    The dies add up fast when you get to the larger sizes but the smaller ones are around $150. I think the bender was around $400. I modified mine for hydraulic power and it works great.

    Unfortunately its one of those tools you probably don't use all the time but when you ned it, its about the only tool you swear is worth every penny.
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  19. blaster11

    blaster11 Still having fun!

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  20. TeneRay

    TeneRay Just glassin'

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    I've used the JD2 hydraulic model to build a couple buggy chassis. It's a great machine.

    I spotted this Eastwood setup: http://www.eastwood.com/professional-tubing-bender.html

    Great price since it comes with a 5 die set.

    Unfortunately, the only down fall is the Eastwood can only do a 90 degree bend at capacity whereas the JD2 can do a 180 degree (with the tube willing without kinking).

    Look into Wood's Metal if your bends start kinking. I personally haven't tried this method but I've seen it done when making sharp bends with thin wall tubing. It's an alternative to sand.
    #20