DIY Project: Metal Bender

DIY Project: Metal Bender

Ever thought about making your own metal bender? In this video, Nate shows how easy it can be to create a simple yet effective tool with just basic materials. Whether you’re working on brackets, frames, or other custom projects, this homemade bender can be a valuable addition to your toolkit. With a little creativity and effort, you can make practical tools right at home. Grab your tools and let's get started!

1. Materials

  • 2'' x 0.065'' Carbon Steel Square Tubing
  • 1/2'' Carbon Steel Round Bar
  • 3.5'' Nom. Schedule 40 Carbon Steel Pipe
  • 3/16'' x 2'' Carbon Steel Rectangle Bar

2. Equipment

Firstess DP200 Multi-Process MIG Welder

Firstess DP200 Multi-Process MIG Welder

KY1101 Multi-Angle Welding Magnets 

  • Angle grinder with a cut-off wheel
  • Tape measure
  • Marker
  • Protractor
  • Dial caliper
  • Step bit drill

3. Building Process

3.1 Using a YesWelder clamp and an angle grinder with a cut-off wheel, cut off a 2'' section of the 3.5'' Carbon Steel Pipe. Proceed to cut the pipe in half so you have 2 half circles remaining. (0:18)

Clamp the 3.5’’ carbon steel pipe, cut a 2’’ section, and split it in half to make two half circles.

3.2 On the 2'' 14ga square tubing, mark an angle at 35 degrees using a protractor on each side and cut with an angle grinder. (0:29)

On the 2'' 14ga square tubing, mark an angle at 35 degrees using a protractor on each side and cut with an angle grinder.

3.3 Using a clamp, secure the 3/16'' x 2'' flat bar and cut off a 2'' section. (0:43)

Using a clamp, secure the 3/16'' x 2'' flat bar and cut off a 2'' section.

3.4 Place one half circle on top of the square tubing so the edge aligns with the angled cut edge. Using a marker, notate on the square tubing where the half circle intersects with the middle of the square tubing. (0:48)

Place the half circle on the square tubing’s angled edge and mark its midpoint intersection.

3.5 Align the half-inch round bar with the mark and mark a cut line on the round bar an inch or two past the end of the angled end of the square bar. Cut two identical pieces of round bar at this length. (0:50)

Align the round bar with the mark, extend the line 1–2’’ past the square bar’s angle, and cut two identical pieces

3.6 Cut 2 sections of 3’’ half-inch round bar. Then cut 1 section of 6’’ half-inch round bar, and set it aside for the last step. (0:52)

Cut two 3” sections and one 6” section of ½” round bar, setting the 6” piece aside for the final step.

3.7 Using a tape measure and marker or a dial caliper, mark a centerline lengthwise down the square tubing. Where the centerline intersects the previous mark that aligned with the half circle, using a step bit drill a 5/8'' hole. Repeat on both sides. (1:24)

Mark a centerline on the square tubing and drill a 5/8” hole at its intersection with the half-circle mark on both sides.

3.8 Using 90-degree magnets and a MIG welder, weld a 3’’ section of half-inch round bar to each end of one of the matching longer pieces of half-inch round bar that you cut in step 5, ensuring the pieces are joined at a 90-degree angle and level. (2:00)

Using 90° magnets and a MIG welder, weld a 3’’ half-inch round bar to each end of a longer piece from step 5, keeping them level at a 90° angle.

3.9 Slide one end through the holes in the square tubing, weld the remaining longer piece of half-inch square tubing onto the ends of the 3'' sections. (2:12)

Slide one end through the square tubing holes and weld the longer half-inch piece to the ends of the 3’’ sections.

3.10 Weld the half circle to the top of the square bar, aligned with the top of the cut angle. (2:29)

Weld the half circle to the top of the square bar, aligned with the top of the cut angle.

3.11 Weld the flat bar vertically about a half inch back from the rear of the half circle on the top. (2:40)

Weld the flat bar vertically about a half inch back from the rear of the half circle on the top.

3.12 Weld the 6'' piece of half-inch round bar to the end of the round bar square coming off at a 90-degree angle to be used as the handle. (2:45)

Weld the 6'' piece of half-inch round bar to the end of the round bar square coming off at a 90-degree angle to be used as the handle.

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Thank you to Nate for the DIY project. 

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