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post #1 of (permalink) Old 03-16-2008, 02:25 PM Thread Starter
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Question how to bend 1/4 in tube for brush guard

well i have had no luck in finding anybody that can bend 2 1/4 to 2 1/2 1/4 in think steel tube for me.... so i got had to very creative in getting the job done...... i cut slots most of the way thru the steel where i wanted it to bend and since it was to be a compound bend also the cuts had to sprial around the tube to let me bend in down and back together.... then had to figure the angle of the mount to the bumper and how to bolt in on thru the plate i used on the end of the tube....... take a look at the pic of this post and it will show the length i went to..... which leaves me with what to do now with all the cuts... open to any ideas but right now i plan on welding most of it back up... grinding it off best i can and using some kind of filler if i need to and or spraying some finish on the brush guard to cover it up... now i have to get the other side the same as the left side...... will post the finish when i get the other side done....
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post #2 of (permalink) Old 03-16-2008, 02:47 PM
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Tell me your not using that jigsaw to make those cuts.

It's not the thing you fling, It's the fling itself!
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post #3 of (permalink) Old 03-16-2008, 02:55 PM
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That'll work. With metal 1/4" thick you can finish it entirely by grinding. Use 60 or 80 grit to get close. Then switch to a 120 flap disk to finish it. As long as your welds are decent there will be plenty of material left after finishing.

And you really don't need 1/4" tube there - 3/16" is plenty. 1/8" is probably plenty. Going too strong is a common mistake, though. You should think of the entire assembly, including the Jeep frame. There's no point in making the bumper, winch mount and brush guard grossly stronger than the frame. At some level of disaster, something is going to get bent. Better it be something you've built and can rebuild than a Scrambler frame that's rare as hen's teeth. Of course it's impossible to design something that will give in the last instant before the frame does, but there's no point to building something that's three times as strong as what it's attached to.

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post #4 of (permalink) Old 03-16-2008, 03:16 PM Thread Starter
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brush guard

no i cut it with a chop saw .... and the steel tube i used is because i just happen to have a couple of these and i was just really making a test on my idea on it... and so far it has turned out so good i am going head and using it... if i dont mess up on the other side... have to do some real hard thinking and planing to get the other side to look the same ... get the bend right and it be the correct length to reach the other end mounting point on the bumper... this is where i could really mess up so i going to stop for now... wish me luck////
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post #5 of (permalink) Old 03-16-2008, 03:18 PM
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.120 DOM works excellent in that situation, but whatever floats your boat.

Ya only go around once, best to enjoy it the first trip.
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post #6 of (permalink) Old 03-16-2008, 03:38 PM
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I dig it.....a creative solution to your problem.

Since its not an ultra critical component i dont see any problem with doing it this way..... I wouldn't do a roll bar like this though

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post #7 of (permalink) Old 03-16-2008, 09:34 PM Thread Starter
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brush guard

oh and i said tube was 1/4 in thick... i sure messed that up,,, it is 1/8 in thick..... still plenty strong just wanted to clear up my mistake on the tube....the steel co i went to did mot have anything else they said i should work amd told me it comes out to anou .0375 or about three times as thick as the 120 dom that i wanted which is why i could not get abody to bend it for me but i got it bent anyway..... going to add a couple of light mounting tabs and a small chain connection to hold up the tow bar... the whole thing is only about 40 in long it really doesnt weigh very much
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post #8 of (permalink) Old 03-17-2008, 08:50 PM
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Kind of reminds me of a giant flexy straw.
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post #9 of (permalink) Old 03-17-2008, 09:58 PM
 
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Quote:
Originally Posted by BMB View Post
Kind of reminds me of a giant flexy straw.
That's the first thing that came to mind when I saw it, LMAO
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