JD Squared 3 - Page 8

Die Set Installation and Bending Procedure
There are two types of forming dies provided for the Model 3 Bender. Those with drive holes and those without. The drive holes
aretheve1"holesdrilledinacircularpatternaroundtheformingdie'scenterhole.A7/8"diameterpininsertsthroughthedrive
links and through the forming die's drive holes when in operation. The drive holes are drilled 1/8" oversize to provide easier pin
installation.Toprepareforbending,followthestepsbelowdependingonthetypeofdieset.
WITH DRIVE HOLES:
Place the forming die into the bender using the 1"
framepin.Ifbendingsquaretubing,thoroughlylubricate
theformingdie'sgroove.However,ifbendingroundtubing
orpipe,NEVERlubricatetheformingdie'sgroove.Ifyou
do,thetubewilltendtoslipbackwardsinthediewhile
bending,whichinturncausesthetubingtokinkorwrinkle.
PlacethetubeintotheformingDie.InstalltheU-Strap
withtheshorter7/8"U-strappin.Ifnecessary,tightenthe
U-strapbolttopreventthetubefromslippingthroughthe
die will bending. It's a good idea to cut a slice out of a
bigger piece of tubing place it between the bolt and tubing
to prevent the bolt from dimpling the tubing. If bending
thinwalltubing(.065"orthinner)youmustalwaysuse
theU-strapbolt.
 Next,usingthe7/8"FollowbarPin,placetheFollowbar
into the bender. See page 5 for the correct way to install
the Followbar. Lightly spray some lubricant on the outside
of the tubing so that the tubing will slide through the Followbar easily. Any spray lubricant works well. If you are bending tubing
withawallthicknessof.065"orthinneryoumaywanttoskipthelubeentirely.Thiswillhelpthefollowbarsticktothetubingduring
ratchet repositioning and generally helps prevent wrinkling. Make sure all pins are completely seated in their holes. Failure
to do this may cause damage to the bender links or worse yet the operator may slip and fall.
RotatetheRatchetLeverfullycounter-clockwise.EngagetheRatchetontotheouter3/4"drivelinkspacertube.Lightlypull
onthehandletopreloadthetubing.Donotpullhardenoughtoactuallybendthetubing.Usingafreehand,loosenthedegree
platenut.Rotatethedegreeplateuntilthedie'spointerisat0degreesandthenhandtightenthenuttosecureitintoposition.
Nowyou'rereadytobend.PullonthehandleinaclockwisedirectionuntiltheRatchetLevercannotrotateanyfurther.Returnthe
Ratchet Lever to the starting position. Initially release the Ratchet easily so as not to move the tubing and minimize spring back.
Reengagetheratchetandpullagain.WhenthelastRatchettoothisreached,returntheRatchetLevertoitsstartingposition.
Removethe7/8"DrivePinandrotatetheDriveLinkscounter-clockwiseuntiltheDrivePinmaybereinstalledthroughanother
holeintheBendingDie.Becarefulnottomovethetube.Nowrepeattheabovebendingsequenceuntilthedesireddegreeof
bendisobtained.Toreleasethetubingfromthebender,removethehandlefromtheRatchetLever.Insertitdiagonallythrough
the3/4"drivelinkspacertubesandpullcounter-clockwise.TheFollowbarwillreleaseitsgripandthetubingmayberemoved.
WITHOUT DRIVE HOLES:
These dies typically have a center line
radius of less than 3". Because the radius of
thedieissosmall,driveholescannotbedrilled
into the die. This does not present a problem
as the tube sizes for these dies is of relatively
small diameter and is easily bent. The ratchet
is not used.
Die installation procedure:
Swing the ratchet assembly out of the
way as shown below. Place the forming die
into the bender. Place the tubing to be bent
in the bender and using the 5 1/4" long drive
pin(nottheshorterU-Strappinthatisusually
used)installtheU-strap.Ifdesired,tightenthe
U-strapbolt tosecure thetubing tothe die.
This is not mandatory and may be omitted if
the tubing shows no signs of slipping through
thediewhilebending.Nowinstallthefollowbarbeingsuretheword'TOP'isfacingup.Rotatethedrivelinksuntiltheirfrontedge
pushesdirectlyontheU-strappinasshowningure6.Placethehandlediagonallythroughthedrivelinks'two3/4"spacertubes.
Lightlypullonthehandletopreloadthetubing.Donotpullhardenoughtoactuallybendthetubing.Usingafreehand,loosen
thedegreeplatenut.Rotatethedegreeplateuntilthedie'spointerisat0degreesandthenhandtightenthenuttosecureitinto
position.Now,simplypullthehandleandobservethepointeruntilthedesireddegreeisreached.
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Figure 14 - Handle installed and ready to bend without drive holes
Figure 13 - Bending with drive holes and ratchet