Summary of Contents for JD Squared 3
- Page 1 odel ender Assembly & Operating Instructions J D Squared Inc. 2244 Eddie Williams Rd. Johnson City, TN 37601 (423) 979-0309, FAX (423) 979-2426 http://www.jd2.com © Copyright 2009 by J D Squared Inc.
- Page 2 D) Place the Ratchet Lever and the 1" Collar on one of the two Spacer Tubes (1" OD tubes). Do not tighten collar. E) Install the Upper Frame Link, Ratchet assembly and 1" Spacer Tubes as shown above. Hand tighten the bolts. Insert the 1" Frame Pin into the 1" Frame Link hole. Slide the 7/8" Frame Pin into hole #5. Tighten the 3/4" nuts as tightly as possible, while insuring the two pins are perfectly vertical and slide easily through their respective holes.
- Page 3 1/2" Bolts & Washers respective holes to help alignment. Lay the assembly on its side to further help alignment and wrench tighten securely. Drive Link 3/4" OD Drive Link Spacer Tubes Drive Link 1/2" Nuts and Washers Figure 3 - Drive Link assembly 4) Remove all pins from the Drive Link assembly. With the word 'TOP' facing up, Install the Drive Link assembly into the Frame assembly using the 1" Frame Pin. See figure 4. The bender is now assembled and ready for the die set to be installed.
- Page 4 Model 3 Bender Hydraulic Adapter Assembly 10 Ton Hydraulic Cylinder Clevis Pin Hydraulic Swivel Block Yoke Threaded Extension Rod Figure 5 - Bender with hydraulics installed. Adapter Components: Excluding the hydraulics: Hydraulic Swivel Block Yoke Threaded Extension Rod Clevis Pin Recommended Cylinder: Enerpac RC1014 or the O.T.C. (Power Team) Part# C1014C or an equivalent cylinder. These porta-power cylinders are rated at 10 tons and have a 14" stroke. On the front of the cylinder is a 2 1/4" x 14 TPI thread. Recommended Power Unit: We offer several hydraulic pumps suitable for the Model 3 Bender. However, any power unit may be used that has an output of at least 1500-2500 PSI. The average bending pressure will generally be below 1300 PSI. Tested examples: 1 3/4" x .095"...
- Page 5 Pipe is much more forgiving when it comes to bending it because of its thicker wall. Stamped into the top is the Outside diameter of the tube or pipe and the centerline radius (CLR) of the forming die. Above is pictured a 3/4" die with...
- Page 6 3) Followbar (Also referred to as the Pressure Die) The Followbar is the component that presses the tubing into the forming die to create the bend. Shown in the illustration below, it consists of three main parts: a backing block and two inserts. This multipart design allows the inserts, if damaged or worn out, to be inexpensively replaced without having to purchase a whole followbar assembly. The Inserts are permanent mold cast from a special bearing grade anti-galling material to protect the tubing from scratching during the bending process and then CNC machined to size. They are silverish in color but are NOT aluminum. Front Straight Notice that one insert is slightly angled. This angle is...
- Page 7 Followbar U-Strap Figure 11 - Square die set components H PLate DEGREE POINTER INSTALLATION Current production forming dies are made to accept a degree pointer. This is supplied as a straight piece of 3/32" copper coated steel rod. The illustration below shows the pointer installed on the forming die. You will need pliers and a wire cutter to fit the pointer. First install the die set into the bender, preferably with a length of tubing installed also. On the backside of the forming die's die block, you will see a thin groove with a washer and bolt installed next to it. Using the illustration below as a guide, bend the wire pointer to fit, making sure it clears the U-strap and drive links. Allow approximately 1/16" clearance above the degree markings. Notice we've placed a small bend in the pointer's lower end so that it aligns with the degree markings. This makes it easier to read when bending. When you are happy with the fit, tighten the pointer lock bolt to secure the pointer onto the forming die. The pointer should...
- Page 8 Die Set Installation and Bending Procedure There are two types of forming dies provided for the Model 3 Bender. Those with drive holes and those without. The drive holes are the five 1" holes drilled in a circular pattern around the forming die's center hole. A 7/8" diameter pin inserts through the drive links and through the forming die's drive holes when in operation. The drive holes are drilled 1/8" oversize to provide easier pin installation. To prepare for bending, follow the steps below depending on the type of die set.
- Page 9 Bending Method #1 - Using Template Bends The Easy Way To Position Bends Learning the operation of a bender is fairly easy. The real challenge is accurately placing the tubing into the bender so that the bend comes out in the right position. This short tutorial ex p lains the simple process of template bending. Make a sample bend called the Template as shown in Figure 15. A permanent mark scribed on the template allows you to measure and visualize where the bend should be placed in the tubing.
- Page 10 Load this tube into your bender as shown in Forming Die Figure 18. Note that only the die set and tubing are visible in the figure. The actual bender and the die set’s u-strap are not shown so that you can see what we’re trying to achieve. Place the scribed line at the flat edge of the forming die. Never use the follow b ar as a ref e rence. If the forming die has a lock bolt on it, use it to securely tighten the tubing in place. It’s very im por tant that Followbar this mark stays in line with the die’s flat edge during the bending process or tem plate will not...
- Page 11 ‘X’ there so that when you load the tube into the bender you’ll be bending on the correct side. Since the desired bend is only 70 and the template is 90 , you will have to use your best judgement of when the template is 25” out. This gets easier with experience. Now, load the tube into the bender and make the first bend. Don’t forget to over bend a little to account for tube springback. For this material 3 to 4 degrees should be sufficient. Since all J D Squared benders are equipped with degree of bend indicators this is easily accomplished. Once you know the correct over bend required, you may want to record it for future reference. 50” BEND 2: Place the template above...
- Page 12 BEND 3: 31” At this step you may want to use a large 90 square to help position the template. Position the template above the rollbar tube with the template line facing up towards the top of the rollbar as shown in figure 23. Slide the template up or down the rollbar tube until its outside is 31”...
- Page 13 20 1/4" 12" the Bending Die. Another example, you want 36" from the bottom to the top of a rollbar. Tube size is 1 3/4" and you have an actual bend start 1/2" inside of the Bending Die's edge. The CLR of the Bending Die is 7 1/2". So: 36" - 1/2" 7/8" (Actual Bend start) - 7 1/2" (CLR of die) - 7/8" (Half 6 1/2" CLR of the tubing diameter) - 1/8" (Springback) = 27". Set Mark the tube 27"...
- Page 14 37 1/4" side. 3) Using the method described on page 4 we determine that the tube should extend 12 5/8" from the edge of the Bending Die. Below is the equation from page 4. 20" (Height of hoop) - 6 1/2" (CLR of die) - 3/4" (1/2 of tube's dia.) - 1/8" (Springback) - 3/4" (Bend Start) = 11 7/8". After making the bend we have half our hoop completed. The top of the bend is 20" from the bottom of the tube. 4) Now for the other bend. First we need to determine how much the tube stretched in the bend area. From figure 9 we see that the tube should be 20 3/4" from the outside edge to our 37 1/4" center mark. However after measuring from our center mark to...
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Page 15: First Method
1/4". Notice we did not subtract an 1/8" for springback. This is accounted for already in the 1/4" we added for the second bend's growth. Set the tube so that the Bending Dies edge is exactly 12 1/4" from the center mark. Make sure the universal protractor reads '0' and the carpenter's level is centered. As one final check you can also measure from the far side of the completed bend to the edge of the bending die. See figure 28. This measurement should read: 40" (width of hoop) - 3/4" (radius of tube not in bending die) - 1/8" (springback allowance) = 39 1/8" Make the second bend. Measure the height of the second upright and cut off the extra tubing we allowed for earlier. Center mark on tube Start of 2nd bend Start of 1st bend 21"...