Poor Mans Jig, Revisited.

[Delmarksman]

Here are my "Poor Mans Tools". I have seen several others using thinner metal and having problems with deformation, I think that thicker metal makes a big difference in getting crisp bends and keeping the flat areas flat, especially the bottom.

I went to a scrap metal dealer and bought as much as I could find in different sizes and lengths @ $0.30/ #. After much contemplation, reading and a few ideas from others,
this is what I came up with. Cost wise, I have less than $15 cash invested.







I started out making all my bends with a 4# hammer, which worked pretty well but was time consuming. After more contemplation, I got some box tubing, 4 long bolts, 16 nuts, drilled some holes and came up with this.



I thought about welding it all together, but decided not to.
If I ever needed to loosen or tighten it up, I can, or if for some reason it warped during welding, or if it spread out from use... I would not be able to adjust it.

(more pics to come, 16 in all, Please stand by)

[Delmarksman]

The rounded inside corners, of the form, help the flat start to bend. I have not had any shearing issues from being tight. Being tight help make clean square bends.



After setting the mandrel and flat onto the form, I take a 0.030" feeler gauge to help center the assembly.



Press it in.



And through...

[Delmarksman]

Off the Upright Mandrel



Onto the Top Rail Mandrel



Into the vise with a pair of 2" Angle Iron and a blue paper towel to protect the faces of the receiver, ready to hammer over the top rails.

[Delmarksman]

Top rails bent.



Removed the cap plate, note the alignment pins.





Ready to start trimming the rails.