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I've got a 15cm length of round tubing approx. 20mm diameter that I need to make into a 'D' shape to fit inside another section. What would be my options for doing it given that I don't have access to any fancy tools, I don't even have a vice - just a hammer, mole grips and usual general tools. I guess I could make a press using threaded rod and a piece of wood? How would I stop it deforming on both sides? I guess I'd have to make some kind of support to spread the load? The tubing is about 1.3mm thick, either stainless or plated steel.
Cheers.
i think packing it with sand helps stop it deforming when bending
Difficult without a former / u-shaped channel to stop it squishing flat. Maybe channel out a thick piece of wood to the right width? Even with a hammer, you'll need multiple blows and expect it'll bounce back.
Packing with sand or hire a pipe bender for £35. I'd spend the money.
I don't think it's do-able, especially for a stainless option. Does it have to be a tube - could you cut it lengthways to make it easier to shape? Or heat it up with a blow torch (tricky for a 150mm length) to make it softer? How good a fit does it need to be?
Could you make a former out of wood (dowling)for the inside diameter,might help shape it easier.
I'm assuming you're talking about squashing one side of it so the section is a D-shape, rather than bending the length of the tube into a big D?
It's not going to be easy or look pretty, but I guess without any sort of vice/press, a hammer is your only option but would probably work with wooden formers on the curved side and/or inside to help shape it. Possibly at either side (the corners of the D) to stop it just getting squashed out.
You'd need some pretty big threaded bar to make a makeshift press, and something equally strong to react the force.
I've actually done this.....
If I understand right you want to make 2 bits of tube that fit one inside the other and have a 'D' shape cross section, is that right? This sounds very like the handle section of a takedown longbow. I've made a few of them. (pics of the last one are on the 'last thing you made' thread).
To form the tube I used a vice - can you borrow one? The process was:
- File off the internal weld so that the tubes fit inside one another.
- put the nested tubes in a vice, pack the space below the tube so when squeezed it can only bulge upwards.
- Squash (carefully) with vice.
-Separate tubes with drift and hammer.
-fettle/sand/polish until the fit is perfect.
I hope that's helpful.
Oh, I assumed it was to make a D shape like a D lock