Tool developed for bending handrails for the BR 20t Brake Van Project - but obviously its use extends beyond that...
Designed for and tested on 0.8mm diameter stainless steel mig welding wire, that is otherwise rather difficult to get a neat, tight, bend in.
It utilises a modified M5 Hex head bolt, with a plain shank element of at least 20mm, cut and slotted at 1 end 5mm deep - see the .STL, just don't expect a 3d printed version to work! It uses a second bolt (or second part of the first one).
It can be used free hand, but I have also included here the test piece used for the handrails specific to the Brake Van - this could be modified easily enough to other lengths.
Models
3D Model
3D Model
Make one fold, slot it in the relevant hole in the jig, fold the other end. Allows for overfolding to allow for spring-back, the amount judged by eye. The small commode handles are folded directly around the M5 slotted pin.
3D Model
M5 Hex head bolt, modified by cutting off the head with 20mm of shank attached, and the end slotted - theoretically 1mm wide x 5mm deep. In truth that means cutting a slot with a hacksaw - nothing technical, and not necessarily even straight! In my case I used an M5 x 60 bolt and the other piece provided the other half. See next model. This model is just provided to show the shape/take dimensions lest my explaination isn't clear - do not expect a 3d printed version to work!
3D Model
as mentioned, made from an M5 bolt. It doesn't need to be threaded, but the thread does make it easier to pull out and push back in the pin. the plain length needs to be about 20mm long - could be a little shorter. Overall length here is 40mm, but again, shorter could be ok...
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