How do you manage to get the bend in the outter tube. Im guessing by using a tube bender obviously but is there any other way. Has anyone welded a piece of tube to each end of a long tube at an angle and then ground them down? I would really like the smooth bends but I havent seen the welded together version to compare it to yet. So has anyone seen this?

 

When I made mine, I used one of those cheap "pipe Benders" from harbor freight. It came out o.k., but not as slick as a real tubing bender. I bet if you are a proficient welder, you could miter cut the ends of the tube and then weld and grind for a smooth finish. If you look at Badland Bumper's sliders they are rounded in the front and boxed, or squared off in the back. WIth something similar to this design, you would only have to make one end mitered...just a thought.

 

If i was to miter in a bend i would try to miter at least two pieces in between the 90. By fittingin 2 pieces the angles wont be as sharpe, which will make it look smoother. When you grind the seam smooth you are losing a lot of metal. Also make sure that you bevel the cuts, leave a little gap and try to "aim" your weld from the inside-out. This will make sure that you get 100% penetration on your weld.

 

Good advise, gdf_77.

 

I will bend up two outer tubes out of 1.75 .120 wall DOM for $50 plus shipping. I'm in CT. I just need the length that you need.

 

Wish i had know this before i bought all my steel. Im thinking i can use a pipe bender here at the school though. i just found out that we have one. Thanks guys.

 

A pipe bender shouldnt be used for tubing. Pipe and tube are different animals. You might end up damaging either the tube or the die in the bender. The tubing might get kinked. But if you decide to do it, post pics. I'm curious to see how the bends come out.

 

Did not know this... Where could i find someone with a tube bender?

 

Start looking at fabrication shops instead of plumbing shops. Maybe a shop that specializes in railings? Or look for a race car shop.

 

northern tool 99$
cheep effective

 

I don't know how much this will help you, but...
I personally used 1.5 inch weld pipe for my sliders, and the rear bumper I just did. I can get it free at my work so It is eaiser for me to used and to replace. I am not an engineer by anymeans, but It seems to me if you bend the tubing it will make it weaker on the outside of the bends. I used an 45 degree cut in the sliders, and used a 1.5 inch 90 on the bumpers, I think I will go back and cut out the 45's just cause it looks better with the 90's.
Pipe is for plumbers, and you should use tubing. But I dont think It is that much weaker. A lot of people buy welded seem tubing, and use it and it is thinner than the pipe I am using. If u buy the tubing, make sure it is seamless. Other wise it defeats the purpose of tubing compared to pipe. But if you use weld pipe, You can go to any pipe place, buy 90's, 45's, and some times 22.5 if ya really want to order them. Weld them on with a wire welder, and have a course grinder there and grind it down smooth. Check for any pit holes, and weld them back over. To do that to one joint will take 10 minutes including cooling time from the heat. If you are worried about the weld breaking, Cool it slower by packing it in sand bags and let it cool slowly. That will give the welded joints more flexability. I don not know if you can buy tube elbows or not, Never had to.
I have seen weld pipe take some major abuse on Jobsites, and never seen it break, unless the weld was not done correctly. But if It is ok to use in a Nuclear plant under high pressures, then I trust it enough on my truck.
That is just my 2 cents. Jeremy has seen the stuff I have done to my truck, It doesn't look as clean as stuff you can order, But only cause I am not to concerned with pretty. Not a major issue with me. If I wanted too, I could get a finer grinder wheel and make it look perfect, But not to concerned with looks like that.

 

Yeh i bought 1.75 tubing with a 1/8 inch wall. I think it should be plenty strong. I bought it from the 4x4 shop up here. I think i might go back there and see if they can make the bend for me
.

 

What size tube are you gonna use? A 1" OD tube is darn close to 3/4" pipe (OD 1.05"). Fill the tube with sand and you'll get a better bend. Or just go and get some black steel pipe and have at it with the pipe bender

 

I could not afford a bender and no one would bend it for me so I just made a few cuts where I wanted to bend and with a little heat I bent the pipe. then I welled the pipe on the inside and got the grinder out.

It is not as precise as it would be with a bender, but looks okay.



It tuned out fine and seems to be strong enough. I hope to finish the grinding and painting next week.