Make A Metal Bender || Homemade Roller Bender

Suthar Sandeep 26794 September 19, 2018 Comments

Introduction

The roller bender is a mechanical device or jig having three rollers used to form a metal bar or rod into a circular arc. The rollers are freely rotate about three parallel axes, which are arranged with uniform horizontal spacing. Two outer rollers, cradle the bottom of the material while the inner roller, whose position is adjustable, presses on the topside of the material.

In this mechanism, after the bar is initially inserted into the jig, the middle roller is manually lowered and forced against the bar or rod with a screw arrangement. This causes the bar or rod to undergo plastic and elastic deformation.

The main problem that people, doing various metallic projects, face is the bending of metallic pieces. The reason that this problem is arisen during these projects is because the metallic pieces need a lot of pressure, strength as well as accuracy to be bent. There are many machines to be used to achieve this but the cost is very high. Therefore, I decided to make for my own. The construction of this roller bender is more user-friendly to everyone, is relatively affordable, is extremely useful and it will fill with feelings of joy and satisfaction the people who want to spend their time productively.

Parts Used :-

  • L-Section channel 1.25”*1.25” width (5mm thickness) 9” length for base
  • L-Section channel 1.25”*1.25 width (5mm thickness) 5” length
  • L-Section channel 1.25”*1.25” width (5mm thickness) 2” length
  • 2 Nos. metal pieces 2”*7” (10mm thickness)
  • Metal piece 2”*2” (10mm thickness)
  • Metal piece 5”*2” (10mm thickness)
  • Metal piece 5”*1” (5mm thickness)
  • 4 Nos. 6301-2RS bearings
  • M12 Bolt (5” length) with 2 nuts
  • M10 Bolt (3” length) with nut
  • 3 Nos. M12 allenky bolts (3” length) with nuts
  • 5 Nos. M8 allenky bolts (1” length)
  • 2 Nos. M4 allenky bolts (1” length)
  • Cylindrical metal piece (1.5” diameter)12.5mm hole
  •  

How To Make :-

Step 1 :- Cutting of parts

First step to make roller bender is cutting of all metal parts to its desired dimension. You can see all the dimension of cutting parts in “parts used”. In this metal bender machine, I have used 4 bearings to use as a roller, also one cylindrical metal piece of 1.5” diameter. This cylindrical metal piece is middle roller and it is manually lowered and forced against the bar or rod with a screw arrangement.

Step 2 :- Assembly of all cutting parts

This is the second step to make roller bender, assembly of all cutting parts. For assembly of parts I have used allenky bolts, I have not doing any type of weld for assembly of cutting parts. 4 bearings are attached with base (L-Section channel 1.25”*1.25” (5mm thickness) 9” length for base), Metal piece 5”*2” (10mm thickness) and 2 Nos. metal pieces of 2”*7” (10mm thickness) by using of M12 allenky bolts (3” length).

Also attach the L-Section channel 1.25”*1.25 width (5mm thickness) 5” length on other side of the metal pieces of 2”*7” by using of 4 Nos. M10 allenky bolts.

Next step is assembly of M12 Bolt (5” length) with 2 nuts and middle roller (Cylindrical metal piece (1.5” diameter) and 12.5mm hole).

This M12 bolt is provide the screw arrangement to manually lowered and forced the middle roller against the bar or rod, and at the last attach the handle to rotate the middle roller.

Handle is attached with middle roller by using of 2 Nos. M4 allenky bolts (1” length). I have used M10 Bolt (3” length) with nut, metal piece 5”*1” (5mm thickness) and wooden cylindrical piece to make handle.

Step 3 :- Ready to use

Now the roller bender is ready to use. In this mechanism, after the bar is initially inserted between the three rollers, the middle roller is manually lowered and forced against the bar or rod with a screw arrangement. This causes the bar or rod to undergo plastic and elastic deformation.

The bar between the three rollers will take on the shape of a cubic polynomial, which approximates a circular arc. The three rollers are then rotated moving the bar along with them. For each new position, the portion of the bar between the three rollers takes on the shape of a cubic modified by the end conditions imposed by the adjacent sections of the bar. When either end of the bar is reached, the force applied to the centre roller is incrementally increased, the roller rotation is reversed and as the rolling process proceeds, the bar shape becomes a better approximation to a circular arc, gradually, for the number of passes required to bring the arc of the bar to the desired radius.

For better to understand, watch the video given below.

homemaderollerbender #homemademetalbender #makerollerbender

Comments

  1. Sam,    [ Layton ]
    September 20, 2018
    Reply

    I appreciate your very informative article and video. Thank you so much for putting all this together. Just one question if you allow me. Where can I get the 1.5 inch Cylindrical metal pieces? Again, I thank you so much!!!

    • Dan,    [ East Tennessee ]
      November 3, 2018

      Cylindrical pieces. This is sold as "round bar". Its solid, you drill out the center for desired diameter.

    • Vikram Panchal,    [ Pune ]
      January 7, 2019

      Whats the Length of solid round bar of 38mm O.D and 12.5MM ID??

    • jack monico,    [ FRANKLIN ]
      March 1, 2019

      steel tubing you can get it at your local metal supply shop

  2. Carlos Arias,    [ San Miguel de Tucumán -Argentina ]
    October 1, 2018
    Reply

    Si es posible la dimensión del angulo y brocas.exelente saludos

  3. Ryan,    [ Bangkok ]
    October 2, 2018
    Reply

    Sam you can get the 1.5" piece at metal supply shop

  4. V.Ramakrishnan,    [ Coimbatore/Tamilnadu ]
    October 10, 2018
    Reply

    Dear Sri.Suthar, I need the finished product of this metal bender and the Metal Drill press vice. Please forward the amount and your bank account so that i can send the payment for them. i have provided my address below: V.Ramakrishnan, U-15, Kovaipudur Housing Unit, Kovaipudur, Coimbatore - 641042. My mobile:8105843368 A message from your side is highly appreciated.

  5. Sujit kuila,    [ Mechada ]
    October 10, 2018
    Reply

    Subject

  6. Ruben Gonçalves,    [ porto salvo ]
    October 15, 2018
    Reply

    pode mandar as medidas exata de cada peça para que eu possa fazer igual

  7. joe bochi,    [ Nairobi ]
    October 22, 2018
    Reply

    Amazing channel... Thank you a million times. Just starting and definitely will save on tools I thought were impossible to buy at this time. Cheers

  8. Khademul Masum ,    [ Dhaka ]
    October 26, 2018
    Reply

    I want hitachi cordless drill machine. Please contact with me

  9. Javier,    [ Brownsville ]
    November 26, 2018
    Reply

    Mamalon👍🍺🍺🍺

  10. mücahit,    [ turkey ]
    December 18, 2018
    Reply

    iyi günler.inanılmaz kanal.benim bu projenin bitmiş haline ihtiyacım var.turkiyede yasıyorum.en kısa sürede sizden haber bekliyorum.lütfen gmail hesabıma mesaj verin. mucahitozdemir2023@gmail.com

  11. Swinder Singh ,    [ Jagraon, punjab ]
    December 18, 2018
    Reply

    Sir! I want to purchase your roller bender machine. I want to know about price and some other details. My no. 09465471449

  12. ,    [ ]
    December 22, 2018
    Reply

  13. ,    [ ]
    December 22, 2018
    Reply

    Please send metal bender price list sir. From. B.r.enterprises. ANAKAPALLI. A.P. phone. 09849966043

  14. B.r.enterprises ,    [ ANAKAPALLI. A.P ]
    December 22, 2018
    Reply

    Metal bender price .From. 09849966043

    • ,    [ ]
      December 29, 2018

  15. Charlie,    [ Las Vegas ]
    January 7, 2019
    Reply

    Always wanted to do a few of these being a welder ..what about a diy plate bender using hinges and the end of a metal table or something? Love your work.thanx

  16. Colin J Niehus,    [ Conder ]
    January 8, 2019
    Reply

    Brilliant work, I must try this for myself,would be very handy tool in my workshop. Many thanks for taking the time to make the video for us, Col

  17. Sanjay,    [ Jaipur, rajasthan ]
    February 7, 2019
    Reply

    Metal bender price

  18. s.ashkar ali,    [ dindigul,tamil nadu, India ]
    February 11, 2019
    Reply

    we need a calculations related to home made metal bender for our project , please kindly request for a give calculations for us

    • Vijay,    [ Madurai ]
      March 16, 2019

      Bro ethum calculation kututhangala..

    • ,    [ ]
      March 16, 2019

      Bro project report iruntha whatsapp bro 7540070885

    • ,    [ ]
      May 15, 2019

      Расчёт толщины металла диаметр трубы умножаем на давление и делим на запас прочности .

  19. Anburaj,    [ Coimbatore,Tamil nadu,india ]
    February 21, 2019
    Reply

    Sir can you give me the calculations for the roller bender please

  20. Sunil,    [ Bhiwandi ]
    February 24, 2019
    Reply

    Very well explained and put on text. Kindly help me as How can I buy a ready one. Sunil 9920695585

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