The $200 junkyard hydro tubing bender - JeepForum.com
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post #1 of 23 Old 03-30-2013, 08:18 PM Thread Starter
Hussler
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The $200 junkyard hydro tubing bender

So I've been building this thing for awhile but I dint want to do a slow *** build for you guys so I'll just do it in one pretty short run. The JD3 bender I used was regular retail like 400 or whatever, but the rest was done for 200, not including some steel. I would like to say before I start this is my first run in with hydraulic anything. Its very easy. My bender should be the equivalent of the one JD2 sells in power and speed. At this point the bender is almost complete, I will update my parts list after its done. Youll see through the pics my plans changed several times, I'm a rapid prototyper. I'll try to keep it concise.

What I used:
-Braun wheelchair lift trim cylinder, $45 at JY
-Braun lift cylinders $12 each x2 at JY
-Braun lines, 2 robbed off 2 different vans 4 total $3 each
-Fisher plow hydro control valve and cables $40ish dollars
-Fisher main feed hydo line $3

Some notes before I get started. Almost all control valves are the same from every plow truck, looking under each hood I would have to say the same company makes all of them. Braun doesnt seem to change their pump sizes/flow rates. Every pump I saw had the same part number even though the vintages were very far apart and the housings were very different.


Quote:
Originally Posted by chris87xj View Post
Sometimes a restoration project is a labor of love, at which point cost, time, and labor involved become irrelevant.
Quote:
Originally Posted by BorderC View Post
I see you also twizzled your scart lead. Well done! :thumbsup:
92 XJ with ARB's, 5" lift, too much armor, 33's and some other garbage
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post #2 of 23 Old 03-30-2013, 08:38 PM Thread Starter
Hussler
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The snow plow valve. Topmost line is the power in line. This is a straightforward connection right to the pump feed. Next one down is the plow up-down feed. That we dont use because its power up but gravity push/fed back. That will get plugged. Those two in the middle are the plow yaw or whatever, thats what will get connected to the outward and inward of the bi directions rams. Last one at the bottom is the low pressure return. That will get fed into a filter and then sent back into the pump reservoir. Note: the Braun pump unit does not have a return so one must be tapped into the bottle.


Quote:
Originally Posted by chris87xj View Post
Sometimes a restoration project is a labor of love, at which point cost, time, and labor involved become irrelevant.
Quote:
Originally Posted by BorderC View Post
I see you also twizzled your scart lead. Well done! :thumbsup:
92 XJ with ARB's, 5" lift, too much armor, 33's and some other garbage
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post #3 of 23 Old 03-30-2013, 08:46 PM Thread Starter
Hussler
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The pump. Neat trait of these units, they have a built in jack in case the van loses power or whatever. See that little round thing in the middle? Electric bypass. Thats how the wheelchair lift lowers, it just feeds the fluid back through the positive line. We dont need that anymore. That leaves us with just the main feed line. The resivoir will need a hole tapped in it for low pressure return. The bottles are nice and thick so this should be easy.



Quote:
Originally Posted by chris87xj View Post
Sometimes a restoration project is a labor of love, at which point cost, time, and labor involved become irrelevant.
Quote:
Originally Posted by BorderC View Post
I see you also twizzled your scart lead. Well done! :thumbsup:
92 XJ with ARB's, 5" lift, too much armor, 33's and some other garbage
Hussler is offline  
post #4 of 23 Old 03-30-2013, 08:51 PM Thread Starter
Hussler
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Heres what the power unit looks like in its case. The cases vary quite a bit, this one was fully loaded with all sorts of BS switches and safty buttons. Dont need any of that crap anymore, just the power unit and its solenoid. Note: You may have caught on by now but this is all 12volt. Ill have a car battery under the bender. Motor only draws like 8amps.


Quote:
Originally Posted by chris87xj View Post
Sometimes a restoration project is a labor of love, at which point cost, time, and labor involved become irrelevant.
Quote:
Originally Posted by BorderC View Post
I see you also twizzled your scart lead. Well done! :thumbsup:
92 XJ with ARB's, 5" lift, too much armor, 33's and some other garbage
Hussler is offline  
post #5 of 23 Old 03-30-2013, 08:54 PM Thread Starter
Hussler
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Here was the first test of all the wheelchair van junk. when you test yours remember that the cylinders are setup from the factory to RETRACT, so you have to expand them to see them work.


Quote:
Originally Posted by chris87xj View Post
Sometimes a restoration project is a labor of love, at which point cost, time, and labor involved become irrelevant.
Quote:
Originally Posted by BorderC View Post
I see you also twizzled your scart lead. Well done! :thumbsup:
92 XJ with ARB's, 5" lift, too much armor, 33's and some other garbage
Hussler is offline  
post #6 of 23 Old 03-30-2013, 08:55 PM Thread Starter
Hussler
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Cylinders attached for ****s and giggles. All the cylinders I ran across took 3/4 pins, which is nice because the JD3 uses 3/4 bolts.


Quote:
Originally Posted by chris87xj View Post
Sometimes a restoration project is a labor of love, at which point cost, time, and labor involved become irrelevant.
Quote:
Originally Posted by BorderC View Post
I see you also twizzled your scart lead. Well done! :thumbsup:
92 XJ with ARB's, 5" lift, too much armor, 33's and some other garbage
Hussler is offline  
post #7 of 23 Old 03-30-2013, 08:56 PM Thread Starter
Hussler
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This was the first piece I cut, an arbitrary 3ft long. The footprint of the bender + ram base bolt barely fit on this 5inch wide I beam but still worked quite nicely. Note: The three holes on that one end is because I ****ed up and lost my orientation. Should be two on one end 1 on the other.


Quote:
Originally Posted by chris87xj View Post
Sometimes a restoration project is a labor of love, at which point cost, time, and labor involved become irrelevant.
Quote:
Originally Posted by BorderC View Post
I see you also twizzled your scart lead. Well done! :thumbsup:
92 XJ with ARB's, 5" lift, too much armor, 33's and some other garbage
Hussler is offline  
post #8 of 23 Old 03-30-2013, 08:57 PM Thread Starter
Hussler
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These legs I end up ditching later and start making a box.
I decide **** it and decide to shape the negative of the piece I cut off to be the receiver for my rams.




Quote:
Originally Posted by chris87xj View Post
Sometimes a restoration project is a labor of love, at which point cost, time, and labor involved become irrelevant.
Quote:
Originally Posted by BorderC View Post
I see you also twizzled your scart lead. Well done! :thumbsup:
92 XJ with ARB's, 5" lift, too much armor, 33's and some other garbage
Hussler is offline  
post #9 of 23 Old 03-30-2013, 09:00 PM Thread Starter
Hussler
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Shaped and welded this is where it starts coming togther. Note: I'm skipping the eyeballing process of where the rams pivot and at what angle the bender gets bolts. This just takes a lot of playing around with the rams until you realize how it needs to move.




Quote:
Originally Posted by chris87xj View Post
Sometimes a restoration project is a labor of love, at which point cost, time, and labor involved become irrelevant.
Quote:
Originally Posted by BorderC View Post
I see you also twizzled your scart lead. Well done! :thumbsup:
92 XJ with ARB's, 5" lift, too much armor, 33's and some other garbage
Hussler is offline  
post #10 of 23 Old 03-30-2013, 09:02 PM Thread Starter
Hussler
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I skipping taking pics for awhile. At this point I added a 1/4 plate on top of the I beam and a double shear plate that links into the topside of the bender. Also welded in a shear plate inbetween the two rams. This pic shows having to drill through all that crap, no fun.



Quote:
Originally Posted by chris87xj View Post
Sometimes a restoration project is a labor of love, at which point cost, time, and labor involved become irrelevant.
Quote:
Originally Posted by BorderC View Post
I see you also twizzled your scart lead. Well done! :thumbsup:
92 XJ with ARB's, 5" lift, too much armor, 33's and some other garbage
Hussler is offline  
post #11 of 23 Old 03-30-2013, 09:03 PM Thread Starter
Hussler
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A pic of the first tubing its ever bent. At this point I was hoping I could run the rams to extend and be able to open the bypass and push the rams back in by hand. Big pile of NOPE! Almost impossible, the rams need to be powered back. See those red lines dangling down? Thats the factory breather/return lines for the unpowered end. That all needs to be replaced with more hydro lines and the snow plow valve.


Quote:
Originally Posted by chris87xj View Post
Sometimes a restoration project is a labor of love, at which point cost, time, and labor involved become irrelevant.
Quote:
Originally Posted by BorderC View Post
I see you also twizzled your scart lead. Well done! :thumbsup:
92 XJ with ARB's, 5" lift, too much armor, 33's and some other garbage
Hussler is offline  
post #12 of 23 Old 03-30-2013, 09:06 PM Thread Starter
Hussler
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Location: utica, new york
Posts: 5,293
Pic of how it sits today. Took the legs off, I'm just going to build a box to hold it up and to contain the guts which will include, power unit, valve, car battery and charger.


Quote:
Originally Posted by chris87xj View Post
Sometimes a restoration project is a labor of love, at which point cost, time, and labor involved become irrelevant.
Quote:
Originally Posted by BorderC View Post
I see you also twizzled your scart lead. Well done! :thumbsup:
92 XJ with ARB's, 5" lift, too much armor, 33's and some other garbage
Hussler is offline  
post #13 of 23 Old 03-30-2013, 09:07 PM Thread Starter
Hussler
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Join Date: Jan 2009
Location: utica, new york
Posts: 5,293
Heres the lever, I'll block off one of those sets of slots, only does one direction now!


Quote:
Originally Posted by chris87xj View Post
Sometimes a restoration project is a labor of love, at which point cost, time, and labor involved become irrelevant.
Quote:
Originally Posted by BorderC View Post
I see you also twizzled your scart lead. Well done! :thumbsup:
92 XJ with ARB's, 5" lift, too much armor, 33's and some other garbage
Hussler is offline  
post #14 of 23 Old 03-30-2013, 09:12 PM Thread Starter
Hussler
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Join Date: Jan 2009
Location: utica, new york
Posts: 5,293
Thats all I have currently, waiting for monday to pick up the steel to make the new base/cabinet.

Quote:
Originally Posted by chris87xj View Post
Sometimes a restoration project is a labor of love, at which point cost, time, and labor involved become irrelevant.
Quote:
Originally Posted by BorderC View Post
I see you also twizzled your scart lead. Well done! :thumbsup:
92 XJ with ARB's, 5" lift, too much armor, 33's and some other garbage
Hussler is offline  
post #15 of 23 Old 03-31-2013, 09:59 AM
schitzangiggles
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That looks freakin awesome. How fast do the cylinders cycle?

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