BULLETIN

December 30 2004 No. ST-10003

APPLICABILITY: STARTECH ST-II BEACH BOY, BEECHCRAFT A-17 AND ALL ALUMINIUM
TUBE CONSTRUCTED AIRCRAFT USING BOB HOVEY CONSTRUCTION OR SIMILAR.

TUBE BENDER
Commercial tube benders are expensive, in the thousands of dollars. We have designed a simple tube bender and
the parts can be turned by any good metal working machine shop.
The accompanying drawings are for inclusion in the BEACH BOY MANUAL and will be sent retroactive to former
purchasers as a service.
Since we cannot supervise the building or use of this equipment, we take no responsibility for its construction or
use. The same WAIVER that comes with the BEACH BOY plans covers this apparatus also.
At the same time we urge builders to exercise due care in the use of this tube bender.
CONSTRUCTION
Construction is straightforward, but there are a few tips for builders.
1.

Leave no sharp edges. Always break (chamfer) sharp corners or edges and finish with 180 GRIT wet or dry
sandpaper

2.

Assemble using Locktite on threads and force (interference) fits.

3.

When building the mandrels, use a piece of mild steel wider than needed, so that the shaped half round
can be drilled using a 1.0 inch or 0.75 inch drill. Then cut the hole lengthwise to produce the half round
mandrel. Finish the surfaces with 180 Grit W or D sandpaper.

4.

Bolt the unit down securely to a heavy workbench. A considerable amount of force is needed to bend tubes.
We did not use heavier than 0.058 inch wall tubing.

5.

Steel should be hardened by heat and quench methods.

6.

When finished, this unit is a handy and useful addition to any workshop.

TIP CURVE JIG (Figure 3-1)

It will be found useful to build a simple tube bender for rib shapes and tip shapes.
1. Cut a piece of 2.0 in. thick Maple pine to the template drawing (Figure 5-1)
2. With a router, mark out and rout a groove around edge. Round the groove out with a round rasp or file.
3. Manufacture the U-piece from mild steel to the drawing shown (Figure 5-2).
4. Bolt the clip in position on the end of the jig.
5. Bolt the jig to the side of a firm and heavy bench or on top flat.
6. Jig is now ready for use.
NOTE: The curvature used is tighter than that of the finished tip or rib. This is to allow the tube to spring
back into shape. Curve is made by trial and error.