Tube Bending

1
Tube Bending

• Using Lever benders
• by
• Robert Charney

2
The Problem

• Create a ½ inch copper tube crossover using
  one 90 degree and two 45 degree bends.
• A is 1.5 inches C/C
• B is 1.5 in. Center of tube to outside of pipe
• C is 4 in. outside to outside
• D is 24 inches end to end

B
B
A
A
C
D
3
The Solution

• Calculate center of pipe to center of tube
  length
• 2 (1/2 of pipe C) plus 1.5 (dimension B)
  equals 3.5 inches which is one half of the offset
  length to the center lines

3.5 inches
3.5 inches
4
The Solution

• Calculate the amount to be subtracted from the
  offset length to center line
• 1.5 x 1.41 2.12 inches
• 3.5 3.5 - 2.124.88 inches center of 45 to
  center of 90

4.88 inches
1.5 inches A
2.12 inches
5
The Solution

• Calculate the length from end of pipe to center
  of 45 bend
• 7 divided by 1.4144.95 inches
• 4.95 - 1.5 3.45 inches
• 12 inches - 3.458.55 inches end of pipe to
  center of 45

7 inches
4.95 inches
12 inches
6
Tool set-up for bending

• Grasp tool by the FORM HANDLE and raise
  SHOE HANDLE clear of the BENDING FORM

7
Tool set-up for bending 2

• Place tubing in FORM GROOVE and secure by the
  LATCH.
• Lower SHOE HANDLE so that the O DESIGNATION on
  the SHOE aligns with the O GRADUATION on the
  form

8
Tool set-up for bending 3

• To bend tubing, use a slow steady motion to pull
  the SHOE HANDLE around so that the O
  DESIGNATION aligns with the desired degree of
  bend on the form

9
Tube Alignment for 90 Bends

• If the desired dimension is LEFT of center.
• Align the MARK with the 90 DESIGNATION on the SHOE

10
Tube Alignment for 90 Bends

• If the desired dimension is RIGHT of center.
• Align the MARK with the R DESIGNATION on the
  SHOE

11
Tube Alignment for 45 Bends

• Measure and mark the location of the bend
• Set up tool
• Position the tool so that the MARK aligns with
  the 45 DESIGNATION on the SHOE

12
45 Double Bend Offsets

• To form an offset, measure and mark the location
  of both bends before bending the tubing.
• The dimension separating the bend locations are
  always twice the offset dimension

13
The first 45 bend

• Mark the pipe 8.55 inches from the end and line
  up on the 45 mark and make a 45 bend

8.55
14
The Second Bend

• Mark the pipe 4.88 inches from the 45 bend mark
• Align new mark with the 90 bending point of
  bender and bend 90

4.88 inches
15
The last 45

• Measure 4.88 inches from the 90 bend mark
• Align mark with 45 location on bender and make
  the second 45

4.88 inches
16
The Last Cut

• Measure the overall length and cut at 24 inches

24 inch
17
You Are Done

• You have created a ½ inch copper tube crossover
  using one 90 degree and two 45 degree bends.