Converting JD2 manual pipe bender to hydro..

[Firemanray]

I recently purchased a JD2 pipe bender to add to my fab equipment. I put it together and attempted to bend a piece of 11g 1.75" HREW tube with it. Who needs a gym when you've got one of these things. NO WAY am I building a cage or anything else major having to pull that hard to bend pipe.

I began some research over in that scary wasteland where the one eyed dude with a hook for a hand lives. I found a couple of write ups on converting the JD2 to an air/hydraulic type operation. Having done that I found a cheap way to convert an already expensive bender into an awesome bender, thus this write up.

Here is a picture of the JD2 bender as it sits now:
http://i223.photobucket.com/albums/dd11/firemanray21/67_1__zps4ec7d466.jpg (http://s223.photobucket.com/user/firemanray21/media/67_1__zps4ec7d466.jpg.html)

I purchased this 8 ton air/hydraulic ram at Harbor Freight for under $100.00:
http://i223.photobucket.com/albums/dd11/firemanray21/image_14928_zpseacc539b.jpg (http://s223.photobucket.com/user/firemanray21/media/image_14928_zpseacc539b.jpg.html)

Now I'm ready to get started with the conversion. I'll post pictures and details as it progresses.




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[Firemanray]

My first priority was to stabilize this heavy sucker yet still be able to move it around the shop. I used a 2' x 2' x 1/4" steel base plate to mount the benders pedestal on.
http://i223.photobucket.com/albums/dd11/firemanray21/3FA34A39-3AB5-47DA-AE86-1621704D24A9-18144-00001A41AC242D16_zpscc5b5ffe.jpg (http://s223.photobucket.com/user/firemanray21/media/3FA34A39-3AB5-47DA-AE86-1621704D24A9-18144-00001A41AC242D16_zpscc5b5ffe.jpg.html)

The bender was placed on the plate to determine the best center of gravity then the plate and pedestal were prepped and welded.
http://i223.photobucket.com/albums/dd11/firemanray21/1897B948-3DF3-4BE3-85AF-40B81DFFA298-18144-00001A41B881207B_zps865ff3f2.jpg (http://s223.photobucket.com/user/firemanray21/media/1897B948-3DF3-4BE3-85AF-40B81DFFA298-18144-00001A41B881207B_zps865ff3f2.jpg.html)
http://i223.photobucket.com/albums/dd11/firemanray21/710836EA-AF5B-4E35-A99C-C06543C5355C-18144-00001A41C213BF2A_zps05eeaab8.jpg (http://s223.photobucket.com/user/firemanray21/media/710836EA-AF5B-4E35-A99C-C06543C5355C-18144-00001A41C213BF2A_zps05eeaab8.jpg.html)

Next I set the ironworker up to punch holes in brackets for the jack adapter. I'm using materials I have laying around the shop for this project. The projects I researched all used 2x2 tubing to build the adapter, I found that a 3" channel would work great and I just happen to have several pieces available.
http://i223.photobucket.com/albums/dd11/firemanray21/DA70AF22-ED73-4C53-81F4-4C9B7C5DE2BC-18144-00001A41CB7CC136_zps1c4bbbe9.jpg (http://s223.photobucket.com/user/firemanray21/media/DA70AF22-ED73-4C53-81F4-4C9B7C5DE2BC-18144-00001A41CB7CC136_zps1c4bbbe9.jpg.html)

I ran out of time so I'll continue later......

[Firemanray]

Today I finished up the hydro conversion and it was worth every penny!!
In order for the ram on the cylinder to fit properly it was necessary to enlarge one of the bolt holes on the die driver from 1/2" to 5/8". This piece has to 1/2" steel plates the mirror each other with several adjustment holes in each piece . It is very important when enlarging the bolt hole to keep the alignment perfect. I found that this piece of equipment has very close tolerances. I punched the first piece on the iron worker then set all the stops so the second piece would punch exactly the same.
http://i223.photobucket.com/albums/dd11/firemanray21/0113141443a_zps170d2524.jpg (http://s223.photobucket.com/user/firemanray21/media/0113141443a_zps170d2524.jpg.html)

I then mocked the 2 pieces up in a drill press to show how it can be done without a punch.
http://i223.photobucket.com/albums/dd11/firemanray21/0113141443_zps070de0a4.jpg (http://s223.photobucket.com/user/firemanray21/media/0113141443_zps070de0a4.jpg.html)

Next I mocked up the to brackets that I'd previously punched and clamp the 3" channel to them so they could be welded in place.
http://i223.photobucket.com/albums/dd11/firemanray21/0113141515_zpsa5aae8c2.jpg (http://s223.photobucket.com/user/firemanray21/media/0113141515_zpsa5aae8c2.jpg.html)
http://i223.photobucket.com/albums/dd11/firemanray21/0113141513_zps092ff2f5.jpg (http://s223.photobucket.com/user/firemanray21/media/0113141513_zps092ff2f5.jpg.html)

The next step is missing a couple of pictures due to the need for multiple hands and serious thought process. After welded the double shear pivot brackets to the 3" channel I had to determine the "throw" and "reach" of the ram. This was not as difficult as it first appeared. After determining these parameters I then constructed a 1/2" thick "stay" to be welded to the 3" channel. This will be the anchor point for the ram.
http://i223.photobucket.com/albums/dd11/firemanray21/0113141544_zps1f07be11.jpg (http://s223.photobucket.com/user/firemanray21/media/0113141544_zps1f07be11.jpg.html)

I then installed the ram using 5/8" grade 8 bolts. Presto it was ready to try. I put some pipe in and made a 180* bend.
http://i223.photobucket.com/albums/dd11/firemanray21/0113141608a_zps3fa7a4a1.jpg (http://s223.photobucket.com/user/firemanray21/media/0113141608a_zps3fa7a4a1.jpg.html)
http://i223.photobucket.com/albums/dd11/firemanray21/0113141608_zps0f50d257.jpg (http://s223.photobucket.com/user/firemanray21/media/0113141608_zps0f50d257.jpg.html)

Next I will have to set the notcher up and it will then be "ROLL CAGE" time!!!

[mudslut]

nice!!!!!!!!!!!!!!!!!!!!

[XJ Wheeler]

Awesome ray! That's gonna come in real handy!

Sent via messenger pigeon - i talk, he types.

[oderdene]

awesome

[07Negative]

Badass! I've been wanting the same one!
Where do you speak of? "I began some research over in that scary wasteland where the one eyed dude with a hook for a hand lives."

[Firemanray]

Badass! I've been wanting the same one!
Where do you speak of? "I began some research over in that scary wasteland where the one eyed dude with a hook for a hand lives."

Pirate 4x4:smiley-scared003:

[ETXXJ89]

that is awesome. so I know whos house ill be going over to for my exo skeleton on the Cherokee when I get ready. or who I will pay to make me one like his. LOL

[07Negative]

There is a ton of really useful info on that forum. The banter can get way outa hand with the way some of those guys talk down to one an other. It's like this hierarchy of fabricating or who's got the biggest balls or something. I only read posts and wouldn't participate on that board. Possibly b/c I'm a pussy :)

[Firemanray]

There is a ton of really useful info on that forum. The banter can get way outa hand with the way some of those guys talk down to one an other. It's like this hierarchy of fabricating or who's got the biggest balls or something. I only read posts and wouldn't participate on that board. Possibly b/c I'm a pussy :)

I've been on that forum for a long time, never made the first post, something about getting the "double finger" smiley thrown at me doesn't set well along with the FU that seems to complete every sentence. I like this forum much better even though there is a small population of "hardcore" fab guys here.

[OneArmArrowSlinger]

Awesome build Ray!