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Thread: Ring Rollers

  1. #1
    Iliketobuild's Avatar
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    Ring Rollers

    In the process of building a boat I ran into a problem which required the fabrication of a new tool. The rub rails for the boat are schedule 40 aluminum pipe 2 1/2" in diameter. They require significant bending along a radius of approximately 14'. I tried numerous ways to bend the pipe without a roller and wound up kinking the pipe every time. After consulting some commercial boat builders the general consensus was that a ring roller was needed. Heavy duty commercial ring rollers are extremely expensive so I decided to build one. My design utilizes 7/8" plate sides (that just happened to be the thickness I could find used). The shafts are a little less than 2" in diameter, riding on huge tapered roller bearings that are adjusted for end play using castle nuts and cotter pins. The roller shafts are driven with #80 chain and a huge gear box. I've use a VFD to control the speed and direction of the rollers. All the dies for the roller were made from a piece of 6" diameter steel repurposed from a sewage treatment plant in Michigan. The roller has worked very well, bending huge pipes without any kinking. The pipes are bent then compared to a full-size template of the radius. After the pipes are bent they are split on a band saw. Sorry for some of the pictures, the downloading software rotates them and I can't fix the problem. If anyone knows how to fix this problem let me know, I have more tools to post.



    Ring Rollers-roller-closeup.jpg Ring Rollers-bending-pipe.jpgRing Rollers-img_6411.jpg
    Ring Rollers-2013-03-06_17-58-13_772.jpg
    Attached Thumbnails Attached Thumbnails Ring Rollers-img_6382.jpg  
    Last edited by Iliketobuild; 12-15-2015 at 06:52 AM. Reason: Can't rotate pictures

  2. The Following 5 Users Say Thank You to Iliketobuild For This Useful Post:

    Jon (12-15-2015), kbalch (12-15-2015), NortonDommi (12-11-2018), Paul Jones (12-15-2015), PJs (12-17-2015)

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    Content Editor DIYer's Avatar
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    Thanks Iliketobuild! We've added your Ring Roller to our Ring Rollers category, as well as to your builder page: Iliketobuild's Homemade Tools. Your receipt:


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    Content Editor DIYer's Avatar
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    Thanks Iliketobuild! We've added your Roller Dies to our Metalworking category, as well as to your builder page: Iliketobuild's Homemade Tools. Your receipt:


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    Thanks Iliketobuild! We've added your Radius Turning Tool to our Machining category, as well as to your builder page: Iliketobuild's Homemade Tools. Your receipt:


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    Quote Originally Posted by Iliketobuild View Post
    ...
    Sorry for some of the pictures, the downloading software rotates them and I can't fix the problem. If anyone knows how to fix this problem let me know, I have more tools to post.
    ...
    I've noticed the problem and it has to do with a site's software configuration for displaying images. Sometimes the wide images are rotated (as seems to be your situation) and sometimes tall images are rotated. The simple 'solution' is to crop a copy of your pics to be sorta close to square. (I don't know how close; my experience is they don't have to be exactly or even really close to square, but you might need to experiment.) Hope you get it working, cuz I sure want to see more!

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    Paul Jones (12-17-2015)

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    Carpenter & blacksmith Philip Davies's Avatar
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    Admirable!

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    Leprechaun, thanks for the tip. Will try it on the next post.


    Bob

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    It was fun to make but took lots of precision machining to get everything to fit and work smoothly.

  11. #9
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    Speaking of precision machining, I like the large-sized radius cutting tool you built for your lathe. Looks like it can handle some large parts.

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    Yes, it works surprisingly well, made it out of some scrap material I had laying around. It is custom fit for my 13" Southbend lathe.

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    Paul Jones (12-18-2015)

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