Bending aluminum tubing

[Darin Clark]

The arrival of the Cabela's and Mack's waterfowl catalogs made me realize I better get busy on my boat. I wanted to add a spray dodger this summer. I watched some DIY videos on the sail rite website and think I have a plan for the sewing, but I would like some input on bending the aluminum tubing. Online I saw recommendations of filling the tubing with sand and bending around a wood frame. Any other advise from those that have done it? Thanks

 

[Dave Diefenderfer]

Darin, as you noted, some of us used a wooden form.... I bent both EMT conduit, and I tried the water pipe that Dave Clark had advocated.

I decided that the water pipe was too heavy, and was concerned that aluminum would not be strong enough for me. I have attached a web handle to my dodger that I use to hold on when I run the boat, standing with an extended tiller.

I suspect you can use an EMT bender and work your way around a little at a time and get a smooth curve...but I did not have one, and wanted a fair curve and not a bunch of small tweeks. The form was easy to make, and allowed me to make several bows all the same. I did a slightly tighter radius than what I wanted for the final and just spread is slightly to the final dimensions.

 

[Steve Sanford]

Dave~

That is an excellent method! I have always bent EMT around wooden blocks but never thought of that pivoting block. Thanks for posting the images.

BTW: I have never bothered to fill with sand (or shot) - do you?

All the best,

SJS

 

[Dave Diefenderfer]

Steve, I did not fill the tube, though my radius was not very tight. The form worked sweet, and it was well worth the 30 minutes or so I spent creating it. I was able to bend a total of 4 pipes in short order, and they were all the same. The biggest PITA was securing the form as I did not have a bench large or heavy enough and did it on saw horses.

 

[Darin Clark]

Thanks Dave. I like the idea of the added strength of EMT over aluminum tubing. Does the standard mounting hardware fit the emt? I also like the webbing hand hold. Anybody else have any other additions they would do?

 

[Dave Diefenderfer]

Darin, there are fittings that sort of fit EMT. I don't remember the sizes off the top of my head. I know they are a tad loose, but will snug up with the set screws. I think I went with some longer screws to get good purchase, and full thread engagement.

 

[Bill Burruss]

Dave,
That is slick- love the results. I just defaulted to a conduit bender and having some straight sections in my frame when making my dodgers.

-Bill