Eventually, I plan to make a custom safari top. Right now I'm pondering materials to gather according to my needs and what will work best. I was told round tube is easier to bend and less prone to kinking than square. With that in mind, I'm thinking I'll use some 3/4" tube with a fairly heavy wall....the same as what the fold out tongue on my dolley is made of. It has a fairly tight bend to it at really about the same angles I will need to bend the frame tubing for the top and without kinks and relatively no distortion to the roundness. (Hope this is making sense). Anyhow, one question I have is how can I, a DIY'r at home with no bending equipment, bend this tubing? Is there some way anyone here has done it with good success and a good degree of accuracy? I have read that filling the tube with sand and applying heat with a torch makes it easier and less prone to kinking. Any ideas?

 

ja... sounds gooooood.

 

I've heard sand works, fill and pack tube, weld caps on ends and bend. Have also seen tubes filled with water and the frozen. The ice inside works the same as the sand (of course you can't use a torch w/ tube full or ice).
Or see if you can find some pre-bent fittings of the same size tubing and weld those in for the bends.

 

Yeah I have heard about the sand trick also. Any chance you might know someone that has access to a tube bender? Also another approach would be to cut the ends @ 45* and weld the corners together, if you have access to a welder.

 

Find an electrician and try to borrow a conduit bender. Or go to Home Depot with a short section of your tubing, find the conduit bender that fits and grab one. Be aware that benders are sold in cast iron and aluminum versions, you would want the iron for the extra strength.

 

Thanks, but wait 'til your see it!

Weld cap on ends? Does this mean the sand remains in the tube?
I'll pass on freezing. Sounds like I'd need BAF! (big a** freezer)

I hadn't thought of pre bent fittings. I'll have to look around. Thanks.

Actually, I do know someone. But, I'm not sure how tight of a radius he can bend. I'm looking to duplicate the same angle radius of the fiber top on my 1st gen. It wouldn't hurt to ask him...plus, if he has time. He runs a muffler shop.

I had thought of cutting the ends and welding them at the needed angle, but I'd rather have a more rounded surface...less abrasion on the canvas. There is a body shop not much more than a mile away that does welding. I'm fast becoming "friendly" with the fellow. He's about my age. But, I'm not becoming friendly so he'll do things. It's just really a natural consequence of some similarities and the fact we do business there. Nice guy. He put the "Zuk" coils on my runner for me. He seems so impressed with the outcome I think he's considering doing it on his 88' extra cab.

Anyway!!! I digress...

My neighbor has one I'm sure he'd let me borrow. Although, I don't know if he would have a die with the radius...again. I'll ask him. It sure would be convenient.

Thanks all!

 

Another trick used on lightweight copper tube is to use a bending spring.

They are threaded inside the tube but attached to a length of wire.

The spring is positioned where the bend is needed, you bend, and then pull the spring out.

Don't know if it will work for steel pipe though!