Date:         Thu, 30 Sep 2004 16:22:29 -0600
Reply-To:     "Gary Lee, Vanagon Racks" <gary2a@TELUS.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         "Gary Lee, Vanagon Racks" <gary2a@TELUS.NET>
Subject:      Re: Home Made Bull Bars--Pipe Benders
Content-Type: text/plain; format=flowed; charset="iso-8859-1";
              reply-type=original

> I want to construct a front bull bar bumper that looks
> much like the "Projectzwo"-spelling? bumper that was
> discontinued....Does anyone know if this pipe bender
> would

I don't often post on the lists, but here is something I know a little
about.

Pipe and tube are two different things.  Pipe is measured by the ID, is used
to transport gas and fluids, has a rough outside finish, is typically much
heavier than tube and has a thicker wall.
Tube is measured by the OD, is used in structural applications, has a smooth
finish and costs more than pipe.
Tubing is what you use to build things, like tube frame race cars and
furniture. The projektzwo bumpers are made of tubing.
Bending pipe is much easier than tube because of the thicker wall.   Bending
tube is not something you can do (even badly) without significant equipment.

Bending EMT and conduit is relatively easy, but those materials are not
suitable for structural applications.  The bend radius is also to big.

Muffler shop benders are compression benders, unless the shop has a mandrel
bender.  Compression benders produce wrinkles on the inside of the bend,
most people would find this unacceptable for appearance reasons.  Also,
muffler tubing is not strong enough to be used for bumpers.

Personally, I don't think anyone could produce for sale acceptable bumpers
made out of pipe.  I only say this to give you an idea of what the finished
bumper will look like, it will look home made.  The rough finish of pipe has
a crude appearance, the wide radius bends don't look correct and the weight
would be very high.  However, as a home DIY project I say go for it.  You
can also use weld elbows and piece the whole thing together, no bending
required.
It will take hours to grind the joints smooth though.  Also, all the bends
will be either 90 or 45 degrees.  This does not look correct.

Tube bumpers (and other items made of tube) may seem expensive, but the
equipment required to make them costs a lot of money.

In answer to your original question about the suitability of the Harbor
freight bender, the short answer is - no it will not do what you want.  Or,
it depends on how good you want it to look.

My mandrel bender only goes to 2"  :)

Gary Lee
Calgary, Canada
gary2a@telus.net
http://www.telusplanet.net/public/gary2a/rack/vw.htm