How to Make a Rolling Machine for Sheet Metal Work

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1 How to Make a Rolling Machine for Sheet Metal Work Designed and written by Rob Hitchings Step-by-step instructions on how to build a hand-operated machine to roll metal sheet and strip into curves and cylinders PRACTICAL t.id!t Puhl ishing Intermediate Technology Publications 1985

2 Practical Action Publishing Ltd The Schumacher Centre Bourton on Dunsmore, Rugby, Warwickshire CV23 9QZ, UK Intermediate Technology Publications First published 1985\Digitised 2013 ISBN 10: ISBN 13: ISBN Library Ebook: Book DOI: All rights reserved. No part of this publication may be reprinted or reproduced or utilized in any form or by any electronic, mechanical, or other means, now known or hereafter invented, including photocopying and recording, or in any information storage or retrieval system, without the written permission of the publishers. A catalogue record for this book is available from the British Library. The authors, contributors and/or editors have asserted their rights under the Copyright Designs and Patents Act 1988 to be identified as authors of this work. Since 1974, Practical Action Publishing (formerly Intermediate Technology Publications and ITDG Publishing) has published and disseminated books and information in support of international development work throughout the world. Practical Action Publishing is a trading name of Practical Action Publishing Ltd (Company Reg. No ), the wholly owned publishing company of Practical Action. Practical Action Publishing trades only in support of its parent charity objectives and any profits are covenanted back to Practical Action (Charity Reg. No , Group VAT Registration No ).

3 Acknowledgements Financial assistance in the development of this machine and in the production of this manual was made available through the Intermediate Technology Development Group from a grant from the Overseas Development Administration. Their assistance is gratefully acknowledged. Acknowledgement is also given to Rob Hitchings' colleagues at ApT Design and Development, Bleckley, Gloucestershire, who assisted in the production of this manual. Check list 1. Rotate the top roller by hand; check that it turns easily, and that it is not eccentric, bent or damaged. 2. Rotate the handle; check that it also turns easily, and that the two bottom rollers are not eccentric, bent or damaged. 3. Remove the top roller. Check that the two bottom rollers are parallel both horizontally (by looking across the machine) and vertically (by looking at the gap between the rollers from on top of the machine). 4. Check that the handle arm C4 has been welded to crank pin C6 so that it continues in the same direction from spindle 82 as crank box C3. If the arm is attached so that it crosses back over the spindle centre the user will have much less leverage while rolling metal. (Refer to Fig. 14 for correct layout). 5. Check that there is not excessive play in the connecting bars C1, and that the welds on the cranks C2 and C3 are good. 6. With the cranks C2 vertical, check that they are both parallel and that the cranks C3 are both horizontal, and in line. 7. Check that the hand screws G operate freely. 8. Check that the vertical play in the free ends of the top bearing blocks Dis not excessive. Examine all wooden parts for cracks. 9. All moving parts should be oiled. 2

Introduction This manual describes in detail how to construct a simple rolling machine for sheet metal work. The machine is cheap to build and easy to use.

4 Introduction This manual describes in detail how to construct a simple rolling machine for sheet metal work. The machine is cheap to build and easy to use. It can be made from readily available angle, bar, and hollow steel sections, using basic welding and fabrication techniques. The only equipment essential for its construction is a drilling machine, an electric welder, 'G' clamps and basic hand tools. An angle grinder, mechanical hacksaw and a metal lathe would make it easier, though these tools are not essential. Construction can be modified to suit locally available materials. The machine can be bolted on to a strong bench or mounted on the stand described. This machine will be found to be very useful in any small metal workshop to make objects in sheet metal such as stoves, flue pipe, water pipe, buckets, bins, mud-guards, fuel tanks, wind-pump blades, etc. This rolling machine will prove an invaluable tool in small workshops in the industrialized countries, as well as in the Third World. Important notice to constructors The plans and instructions given in this manual must be read very carefully at each step of the construction process. The order described here in which parts are made and assembled is the easiest, and should be followed exactly. Particular care must be given to the relative positions of parts before they are welded. Where materials are not available in the sizes specified in the manual, give serious thought as to how your substitution with material of a different size will affect the function of that part of the machine: - Will the change weaken the finished machine? - Will it make the machine less durable? - Will this substitution alter other dimensions given elsewhere in the manual? Where flat bar or plate of the specified thickness is not available, consider whether you could weld two thinner pieces together around the edges and use this in its place. It is usually better to use a larger steel section than a smaller one. Components which slide together or rotate in one another should not be painted on those surfaces, and should be greased or oiled as the machine is assembled. Further oiling from time to time will also prolong the life of the machine. At the back of this manual is a check list. Please read it both before you build the machine and after you have completed the machine. If all the points listed are O.K. you will be well pleased with your machine. 3

5 Contents page Check list 2 Introduction 3 Important notice to constructors 3 Uses of the machine 6 Description 7 Construction 10 Detail drawings 14 Operation 26 Further suggestions 27 4

Rorty No.2 Tube Bender.

Rorty No.2 Tube Bender. Copyright. This entire Manual is copyrighted to Rorty Design, with all rights reserved. No part may be transferred or copied by any means whatsoever, without the express written permission of Rorty Design.