Cutting/Welding vs bending

[JayRay]

[LEFT]
I am using 1 inch thin wall squres tubing. Overall length approx. 8 fee. I need to make to offsets at one end ...the first approx. 8 inchs at about 35 degrees; the second would only be about two inches in length and parrall to the main tubing. Tried bending but was having problems with pichout and crushing the sq. tubing. Would i lose any strenght by just laying out cutting the pieces necessary to make the bend (form) that i need and welding them back together?
Plus with my bening skills pretty nil...would hop the cutting and wlding method would be a good route to go...thanks for any replies jt

[norite]

Cutting and welding won't weaken it except that it would concentrate the stress over a much smaller area. You might have to weld gussets on the side of the bend to distribute the stress over a larger length of the tube if the tubing is highly loaded.

Other than that, for mass production bending would be faster and cheaper after the expense of acquiring a proper bender to do this. For a one off project, I'd cut, weld and gusset the joints depending on what you are doing with it.

[forhire]

+1 for Norite's answer.

I'm a fan of bending when practical. You might post some pictures of your attempts and your setup and someone may be able to lend some advise.

The radius and material thickness will play a huge part in how tight of a bend you call pull off without crinkling. Collapse of the top inside is common on square tube and often acceptable. With thin wall (0.065) I think a 4.5" radius is about as tight as you can do. I'd try 5.5 to 6 unless you really need it tight. Larger radius bends are easier and smoother than tight ones.

A homemade tool, similar to a conduit bender would be worth trying. I found this video that should give you some ideas for making one on the cheap. It's kinda humorous also...

http://www.youtube.com/watch?v=vguWbHxzG98

[brslk]

Hay, thanks for the vid forhire.
Such a bender may be my next project. Only issue is that I don't have the weight that "meathead" has to use as leverage. Perhaps a longer handle?

[forhire]

Hay, thanks for the vid forhire.
Such a bender may be my next project. Only issue is that I don't have the weight that "meathead" has to use as leverage. Perhaps a longer handle?

Longer and beefier handle would be in order.

I found this bender that is similar. It's a 5" radius, which I think may be too tight for the 18 gauge he's bending based on the wrinkling. I bet if it was 6" it would be wrinkle free. Note how he put a ridge in the die to assist the collapse of the inside corner.

http://www.metalgeek.com/archives/2005/05/01/000047.php

[gordsgarage]

This was my solution to bending thin wall square tubing.

http://gordsgarage.wordpress.com/2010/11/01/bent-outta-shape/

Depending on how tight the bend needs to be cutting and welding may be the way to go.

Gord

[JayRay]

Gott'er done...(camera not working right now); but here is what I did. I took a piece of solid
tubing, about 5/8 in. I believe. Bent it to the shape that I needed..think of a "coat hanger"
(without the hook) and that is about what it looks like. Took some 3/16 clips and welded to the jig and to my welding table, this put the jig pretty much in the center of the square tubing. Clamped the square tubing tightly up against the jig and to the table, and slowly made my bend, insuring that I kept everything lined up. The bend didn't crimp at all. I had to loosen and slide the square tubing abit to keep from getting to tight of a bend.But for a first try I think it turned out pretty good. As soon as I get the camera working will put some
pictures up so comments can be made on the jig and the bend. Thanks for all the replies and good info. jr

[weldbead]

you could make a "piecut" to facilitate this.cut out a threesided wedge, bend the piece thats left and weld three sides back..