Never heat this filler in any other way than the prescribed method, as the alloy will stick to the inside of the tubing, making them both unusable. It can be re-melted and reused as often as desired. Store the fusible alloy filler where it is free from dust or dirt. Visually inspect with a borescope to make certain that no particles are carried into the system in which the tubing is installed. When using either filler methods, make certain that all particles of the filler are removed. After the bend is made, the alloy is again melted under hot water and removed from the tubing. The alloy-filled tubing is then removed from the water, allowed to cool, and bent slowly by hand around a forming block or with a tube bender. In this method, the tube is filled under hot water with a fusible alloy that melts at 160 ☏. In a modified version of the filler method, a fusible alloy is used instead of sand. After the ends are closed, bend the tubing over a forming block shaped to the specified radius.
Both plugs must be tight so they are not forced out when the bend is made. Could not be cheaper to make.After plugging one end, fill and pack the tube with fine, dry sand and plug tightly. for tight bends I bent some steel round one end similar to a conduit bender pivot. Keep matching it against a form that you want it to match. Fasten two 9" diameter to the sides looks like a pulley. glue up 1/4" to the 3/4) and 7" in diameter. I cut 3/4" plywood into three half circles. I bent them, and they came out very nice on a wood mandrel I made. The bows are 44.5" wide and matched the curve of the Plexiglas. 049 square tubing for the canopy Needed two bows and the instrument panel. Still need the parts, project completely stalled till I do.Ĭan anyone in this forum point me to a company local or even not local that can do the job? Or identify a tool or method that I can use to bend these myself? I sent a part sample as pattern before Christmas and now I can not get them to answer emails or phone calls. My first choice, have Aero Adventure (FL) do the job, they said they can. Helens OR that advertised mandrel tube bending and they just told me "no can do". As this sort of thing quite common on many ultralight designs, I figured living in Portland metro area home of Van's aircraft and several other kit aircraft businesses, I should have no problem finding a shop to bend thin wall aluminum tube. several tight bends required in 6061-t6 1" dia, 0.049" and 0.065" thick walled tubes. Have several parts to fabricate for a Buccaneer 2 project. If they can't do the work, they should know who will. Find yourself a local hydraulic supply house.
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