Flattening a metal tube, HELP!!

[Jeff May]

Hey all,
I have some 3/4" DOM tubing that I need to put flat ends on in order to bolt the tube to a tab.
I tried just putting it in my press, worked ok. Was not like what I have that I need to replace.
I have some pics attached so you can see what I need to do.
I'm assuming there is a die of sorts used to do this.
Can anyone offer some suggestions? How about you guys that build your own tube chassis?

 

[kd4gij]

Yes you will need to make a die set to get that shape. You can make them, what tools do you have?

 

[kd4gij]

I would take 2 pices of 1/2" x 4" x 3" any steal and pin or bolt them togather. clamp in the mill vice with the 3" up and down. Mill it leaving a 3/4" x 1" stup sticking up in the middle the hight of the indent. then grind the radius to match the part. then use a couple of 2 1/2" long bolts so you can open it up. I hope that makes scence.

 

[RandyM]

What about just welding the flat to the tube?

 

[Malave16]

What exactly are you triying to accomplish? If you le us see the whole picture we can come up with some ideas. I would take a hole saw of the same diameter of your tube and make a hole into some angle iron. Then cut that section and weld it in. Square tubing would work too, and you can cut off the unneeded sections afte its secured to the tubing.

 

[Don B]

I'm not saying this is right, I struggle with this kind of stuff, I did this once and was able to get reasonable results, I flattened a scrap piece first to find out the finished width, I turned 2 pieces about 1/8 larger than that size, one piece was drilled and a hardened pin installed (long enough to include the diameter of the tube plus extra to go into the second turned piece) the second turned piece I put a hole that was a sliding fit with the pin, I drilled accurate (in the center) holes through my tubing, slip the tubing on the pin put the second turned piece on and squeeze the crap out of it.
I was able to get the flats accurately located with the holes in the center and they all looked the same.)

Edit; I forgot this part, one thing I never took into account for was winding up with an oval hole, it didn't affect me for my project but if you try this and a round hole is important use an underside pin and open up the hole afterwards.

 

[TOOLMASTER]

2 3 ft pieces of 2x2x1/4" wall hinged on end.with 1/4" plate .one big pliers.

i'll leave the rest to your imagination

 

[dickr]

Is this for one or 100 parts ? If it's production a die or tooling is best. Then drill afterwards. Shape the end before you flatten. You'll need to experiment a little and learn a lot.
dickr

 

[Jeff May]

For now I think I will only need 4 or 6 pcs.
They are the ends that attach a front bumper and side nerf bars on a vintage racing go kart.
The ones on it now are either bent or totally missing.
I need to fab these pcs. up, fit them and send them out to be chromed.
I was experimenting the other night with some electrical conduit, decent results.
Tried it with the same material the kart is made from and the edges cracked.
I'm still experimenting when I have time.
This is what I'm trying to end up with.

 

[chips&more]

I know it looks easy, but the effort in tooling and knowledge to get to the finished product is very challenging, especially for the HM. I once had to make supports that go in the engine compartment of a 65 Mustang convertible. It looked easy, just smash the ends…Huh! About three weeks later and several attempts at different dies, filing the tube up with sand, torching the end and I can’t recall all the swear words I used. I finally got the results that I was looking for. In a nut shell and I’m not coming from a factory environment that does this kind of thing daily. I used a die and torched one side of the tube and smashed it rather quickly in the die…I wish you a very Good Luck.