Today, I finished my first prototype of a jig that bends Tapco Flats. The overall design and credit for this jig is given to SKS_Hunter and his sidekick Hotbarrel. It has been months since they originally showed us this beauty, but it has taken me a while to get it started/finished. SKS_Hunter and Hotbarrel's jig, picutres, and info. can be found on GUNCO here.
Hotbarrel, gives a basic outline how he did his. I used the idea and took my own measurements to design mine. It took me about an hour and a half to draw it up on Solid Edge, and it was ready for the mill. Like SKS_hunter says, these jigs could easily be made up with a drill/drill press and dremel. But, since I have access to milling equipment, I took advantage of it. Like I said, it is my first one and needs some improvements on the locations of the dimples for the sides, and some other few minor changes. I just finished it this evening, and haven't had a chance to test it, but I'm sure it should work quite well.
I did add two hole for locator pins that I added. The alignment of the flat exactly in the center of the thinner flat bar is essential for the bends to come out correctly. Instead of allen screws like some have done, I will be using a 1/8'' dowel to locate dead center. This should keep me very lined up centerwise with no interference or small movements from screw threads on the pin. I know a threaded dowel will work perfectly as others have done, but I decided to got this route my first time. In the picture, is the dowel that I will cut to length to use.
If you have any questions, please feel free to ask.