Radiator Tube Bead Forming

[MP&C]

Had someone stop by the shop needing to add a bead to the end of the aluminum tubing he had to install in his Cobra project. He had trimmed one end for a better fit and needed to replace the bead for the radiator hose...

......to match the other end.

The dies on the bead roller were much too large in diameter, so I thought to make a manual device out of a pair of vise grips... Once the teeth start to wear these make ideal candidates for purpose-built tools. For the punch part of the tool, started with a thick 5/8 washer and gave the edges a nice radius in the lathe.

The vise grip bottom teeth were welded in and sanded smoothed to provide a flat area for the punch to push against (for less marking of the tubing), then an 1/8" thick 3" dia cut off wheel provided the recess in the lower jaw of the vise grips.

The washer was notched and bent to better fit the vise grips for welding....

Masking tape added to use as a reference/stop mark to align against end of vise grip jaw.

The vise grips with their adjustable jaw setting work well to make one revolution, then adjust tighter, etc..

Finished product....

 

[Brad54]

Damn. That's slick!

Well done.

-Brad

 

[chris fresh]

saw this trick a few years ago on another board,great re use of a worn tool.only thing it didn't have was the tape idea,wich is a great idea.nice work!

 

[Test Tech]

That is great, definetly a fatastic use of vice grips that are past their prime.

 

[e-tek]

You're a frikken' genius Robert - seriously


I just saw a set of purpose-made dies for this very job, but thought "too expensive for the one or 2 times I'd use it". This method is way more reasonable.

 

[Dick in Wisconsin]

All the aluminum tubing (radiator and fuel cell vent lines) had a beam of aluminum welding around the tube near the end.

I do like this tool. Does the Lisle tool company pay for ideas? Better submit this one to them. If they are lurky on this Forum them might already have this in proto-type!

 

[ny1]

What a awesome idea!!

 

[HOTFR8]

Very nicely done.

 

[larry4406]

Very clever. A large stainless steel band clamp around the tube would provide a postive stop for the tool vs the tape.

 

[383 240z]

thank you, I, like E-TEC have been wanting the tool that does that. Like this one: http://www.chicagoconnection.us/images/earls/008ERL.jpg But they are about $30 each. I'll be building a set of those real soon. Keith

 

[MP&C]

Thanks for the comments guys, I too had been wanting a tool to perform this function but could never justify the cost just to have the tool. The vise grips, which I bought used for about $5, made much more sense.

thank you, I, like E-TEC have been wanting the tool that does that. Like this one: http://www.chicagoconnection.us/images/earls/008ERL.jpg But they are about $30 each. I'll be building a set of those real soon. Keith

Keith, $30 ea for the smaller, heater hose sizes. For the larger sizes like the 2" pipe I modified, their tool is closer to $75...

Very clever. A large stainless steel band clamp around the tube would provide a postive stop for the tool vs the tape.

Larry, that was my initial thought as well, to use a hose clamp for the "stop". Then I thought about all the scratches I'd be adding to the nice polished aluminum, so the tape was the second option (and the roll was sitting there ) I did have three wraps on the tape, so it did provide somewhat of an edge. With a bit of patience exercised, the tape seemed to hold up well.

 

[steel 35]

Marked for another project!

 

[bad_idea]

Beautiful home made tool. I find myself making a fair amount of tools, jigs, fixtures, etc to save a trip to the store or worse yet the long wait for something ordered online.

I once had a transmission hose snagged off of a 5/16 section of tubing when I ran over a small branch/twig with my 79 Camaro. I found out I had a line loose when driving down the road a cloud of smoke started billowing out from under the hood. I had just put that engine and trans in! How would you go about rolling a bead on a 5/16 line? Sorry for the thread jack. Again, beautiful home made tool.

 

[HOTFR8]

How would you go about rolling a bead on a 5/16 line? Sorry for the thread jack. Again, beautiful home made tool.

In that situation I would add a few bead or spot welds to make a lip.

 

[bad_idea]

What is a "few bead"? I'm not trying to be sarcastic, honestly confused. I understand the spot welds though, will tuck that tip away for future use. Thanks.

 

[MP&C]

I once had a transmission hose snagged off of a 5/16 section of tubing when I ran over a small branch/twig with my 79 Camaro. I found out I had a line loose when driving down the road a cloud of smoke started billowing out from under the hood. I had just put that engine and trans in! How would you go about rolling a bead on a 5/16 line?

Years ago I also used some hose splices on tranmission lines, and it never seemed a permanent fix, the heat and trans fluid seemed to wreak havoc on the hose where it did not last long at all. Plain and simple, the most permanent and maintenance free method is to get a tubing bender and make the trans lines in one piece, flared to match original. The hose is a failure waiting to happen, leaving you stranded in need of a repair. (especially as sorry as today's rubber hose is). But if I were trying to flare that tubing for hose, I have one of the hydraulic flaring tools that will do the bubble flares. A partial flare using the bubble flare die would leave a good bead for sealing the hose.




We tried the tool on stainless tubing today, 2" OD, .06 wall thickness.

Set the "stop" using tape again...

First pass....

Second pass....

Third pass....

At this point we were about .06 over the original diameter, which was about the same result we did with the aluminum.

We could have made another pass and made the bead more pronounced, but this process looks to be a viable option for the stainless tubing for the wall thickness we used...

 

[HOTFR8]

What is a "few bead"? I'm not trying to be sarcastic, honestly confused. I understand the spot welds though, will tuck that tip away for future use. Thanks.

I was trying to say a short weld or what I would call a bead weld. Just make a lip with a welder.

 

[e-tek]

On a side note, nice photo`s - What are you using for a camera?

 

[MP&C]

Thanks, Canon SX120IS

 

[87Pomona]

Where did you get the washer from? I've searched Home Depot and they dont anything close to 5/8.

I saw a tool very similar to this a few months back on an Eclipse Car forum, it was as nice as yours though.

Good job on the tool and pictures!

 

[johno]

Nice!!!

 

[johno]

Beautiful home made tool. I find myself making a fair amount of tools, jigs, fixtures, etc to save a trip to the store or worse yet the long wait for something ordered online.

I once had a transmission hose snagged off of a 5/16 section of tubing when I ran over a small branch/twig with my 79 Camaro. I found out I had a line loose when driving down the road a cloud of smoke started billowing out from under the hood. I had just put that engine and trans in! How would you go about rolling a bead on a 5/16 line? Sorry for the thread jack. Again, beautiful home made tool.

You can use the first part of a double flare for that.

 

[MP&C]

Where did you get the washer from? I've searched Home Depot and they dont anything close to 5/8.

You'd probably have better luck at a Tractor Supply store (or similar), although I don't know where mine came from....it was in the hardware drawer.. The one I used is a little over 1/8" thick.

 

[thruthefence]

I have an old set of vice grips that I made a sheetmetal "joggle" tool out of, i a similar fashion.

This is very timely, because I need to bead the radiator transfer tubes on my Lotus project, and your idea is perfect!!

Permission to shamelessly copy?

 

[NASTYZEN]

Now that is darn crafty of you Robert. I always thought rollers for that kind of job. Never would of occurred to me to crimp away. You clever devil you.

 

[porschedude996TT]

I must say "Well done!"

 

[gerahead]

I once had a transmission hose snagged off of a 5/16 section of tubing when I ran over a small branch/twig with my 79 Camaro. I found out I had a line loose when driving down the road a cloud of smoke started billowing out from under the hood. I had just put that engine and trans in! How would you go about rolling a bead on a 5/16 line? Sorry for the thread jack. Again, beautiful home made tool.

The flaring tool that I have (Snap-On) has a set of dies included to make a bubble flare at the end of small hard line like this. I have personally never used it because I have only done double flare work with it. As I recall, the set wasn't all that expensive. Especially considering that I bought several cheaper versions that were junk before I got this. L8r

Jim

 

[henrysgarage]

One again nice work Robert. Here is the tool a fellow here did to make the flair for his intercooler.

 

[207racing]

bringing this post back from the dead....

Spent a couple hours making the same tool today. Then about 15 minutes to put a bead on an aluminum radiator outlet!! But now I have the tool should I ever need it again. Thanks for sharing your idea!!!

 

[MP&C]

Glad to help! Some of the store bought versions may do a bit nicer job in making the bead profile, but a used pair of vise grips are quite a bit cheaper, saving money for other tools. Once the hose goes on, they look exactly the same..

 

[t-spec]

Man that's a really slick idea!

 

[jimindm]

In that situation I would add a few bead or spot welds to make a lip.

I have used a compression fitting before. Compress the fitting, then cut the nut off of the line.

 

[Trey T]

Whats the smallest tube can you roll with the custom tool, 1"?

 

[iajonesy]

Robert,once again you've shown why you are my hero.

Mike

 

[383 240z]

I've said it before, and I'll say it again. That tool is ****. Keith

 

[MP&C]

Whats the smallest tube can you roll with the custom tool, 1"?

The end of the Vise Grip should accommodate that size. I'd say if you can get a washer small enough and yet still sturdy enough, you should be able to make one to do the job. Or use a piece of 1/8 flat bar to use as the 'Press"