as polishing the 3"x3"x1" bar and the. 1" round bar roller may be difficult for you - you don't want to leave marks on the item that you are bend- ing. There may be ...
METAL BENDING This particular bender was made to bend the aileron horns used on biplanes. It is designed to bend 1/4" 2024T-3 aluminum cold or "as is" condition. This particular horn is used in several aircraft including Pitts Specials and Acro Sports. It is extremely difficult to bend this size material correctly without cracking or
Bend
scratching. Dan Reed, EAAer of Salina, KS (913/823-2248) designed this particular unit. One of the problems he encountered was that the original 4" wide vice was inadequate and broke under the strain. A vice designed for heavy duty work is essential. The lever arm on his handles were 2' long and he felt that it could
even have been longer. Be sure to remember the scrap aluminum on both sides of the pieces to be bent as polishing the 3"x3"x1" bar and the 1" round bar roller may be difficult for you - you don't want to leave marks on the item that you are bending. There may be other uses you can find for this bender.
SIDE VIEW - ALUMINUM BENDER IN VISE
Control horn to be bent —.020" Scrap Aluminum on 2 sides — Protects the Horn—IMPORTANT! Tape scrap in place. Handle
Bench Vise The Stronger The Better!
GEOMETRY OF AILERON CONTROL BENDS
BENDER
Handle length as required, this is about 2'. 1" Round Bar 3"x3"x1" Steel Bar (round top end)
approx. 90 SEPTEMBER 1992
This side view shows the handle just in contact with the scrap aluminum used to protect the horn. The scrap aluminum is a very important part of this operation and it keeps from marring the piece that you are working on. We would like to remind you again that the bench vice has to be super strong for this operation due to the leverage involved, as is the bench it is bolted to. A similar possibly modified and larger bender probably could be used for bending aluminum or steel of a larger size. The 1/4" thickness seems to be about the maximum partical thickness to bend cold to these particular angles.
1/4x1" Flat Bar Typical
3/8" Diameter Bolts This bender is made in mild steel. If you are going to lengthen the arms, it's possible that angle iron may
make a stronger handle. The 3"x3"x1" steel bar should be well polished on the top end as should the 1" round bar.
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