Need to flatten thinwall pipe ends for structural use. Ideas on methods?

[DR]

Like so: https://www.youtube.com/watch?v=g9Kr2tSTVew

Did you notice about 1 minute in, lower left, you can see a worker with sandals on, exposed toes.

That's a pretty hokey operation. With a simple die they could assure the flat is on one side and could eliminate the straightening operation.

[J Tiers]

...... I tried to give it one more shot. I'm done with you. All you like to do is argue with your ignorance.

?????

Probably I should be glad, you are quite grumpy, and it shows. "Ignorance".... LOL..... you cannot find ONE statement I made that is wrong, but don't answer, I won't see it.....😁

[pb57]

Why ask if all you want to do is pick apart answers you get. If it was me I would use the 50 ton press I made and if I didn't have that I would use the hammer and bench and it would still look good. Have you ever done simple projects like this before?

[Corbettprime]

Techspecs are for techs. If I go into HD and ask for conduit, guess what I 'll get? I'm betting on thin wall stuff. I like the idea of the notched die and the hydraulic press. Great reason to buy one. I used that rationale to justify buying an engine hoist to load and unload that little SB 9" I bought. Because it was a floormount model, I'm guessing 800 to a 1000 lbs from the way it set the trailer down. I'm looking for a set of the short brackets to convert it to a bench mount. Figure I can weld up a motor/pulley bracket. I forgot to add that if I go into Consolidated Electrical Wholesale and ask for conduit, I'll get the heavy wall stuff. Just depends on where you shop.

[CCWKen]

Everyone around here knows what conduit is. I can ask for metal or plastic in a size and they know exactly what I'm talking about. I don't know where you shop but conduit may or may NOT be EMT. --- I tried to give it one more shot. I'm done with you. All you like to do is argue with your ignorance.

[J Tiers]

"What does "structural" mean to you? In what context?" --- I'm referring to an ASTM standard like A36 for construction components. I wasn't aware that "conduit" met any of those standards. If it does, now I'm educated. The 1/2" conduit I'm familiar with could bend easily. It wasn't very precision either. Perhaps it was from a foreign source. I like KMoffett's method--No welding.

For many "structural" applications, A36 is unacceptable. It's all about what structure, what loading, etc.

What you call "conduit" is NOT conduit. It is "EMT", "Electrical Metallic Tubing" (Article 358). Actual "conduit" is threaded and is essentially pipe that is smooth on the ID. Various scheduled pipe is in fact used for structures, and "actual conduit" may be equivalent to specific scheduled pipe, in which case it is "structural" in that way as well.

As it happens I am making a small "structure" to hold up some reasonably light things, and EMT will do fine. You mean EMT can bend? SHOCKING! Heavy bridge beams have a bending load also. The "structure" is designed in part by selecting beams etc that will not be loaded to yield until the margin/factor of safety is exceeded.

[nickel-city-fab]

you know, I have done this with a 2-lb hammer on the fab shop table at work -- they needed a new x-brace for their scaffolding. Just keep pounding on the same side, it'll flatten don in that direction.

[CCWKen]

"What does "structural" mean to you? In what context?" --- I'm referring to an ASTM standard like A36 for construction components. I wasn't aware that "conduit" met any of those standards. If it does, now I'm educated. The 1/2" conduit I'm familiar with could bend easily. It wasn't very precision either. Perhaps it was from a foreign source. I like KMoffett's method--No welding.

[metalmagpie]

I built a geodesic "desert dome" from EMT. Each of the hundreds of lengths had its ends flattened. I did them all with a Famco 3-1/2C arbor press very fast and accurately.

metalmagpie

[J Tiers]

Forgot to mention: You do know conduit is NOT structural, right?

Well, actual threaded conduit is burr-free pipe, so it is as "structural" as pipe is, according to its size and wall thickness. Pipe, even standard pipe, is quite "structural". EMT, which is what I am referring to, is thinwall, annealed, and is therefore somewhat less "structural" in terms of the loads it can carry.

Flattened end joints are not particularly "structural" either, if it comes to that (at least for compressive loading). But for light weights and short lengths, EMT is plenty "structural" enough.

What does "structural" mean to you? In what context?

Glass is not particularly wonderful "structural" material, but it is commonly used, without reinforcement for certain types of unfired pressure vessels. I'll leave it to you to figure out what those are.

[KMoffett]

I've done this to make conduit braces and pointed stakes. The dies are made from old bed frame angle steel, heated and reshaped. Use a heavy duty vise as it takes a lot of force.

[CCWKen]

Forgot to mention: You do know conduit is NOT structural, right?

[CCWKen]

When I built my Kenbota front end loader, I used a piece of angle iron welded to the end of 2" pipe. There was no need to "smash" anything and it looked better. I can't post pictures any more so you'll have to wing it.

[J Tiers]

How does one control the offset with a vice?

Check post #2. Simple and it should pretty much work, aside from the straight "fold" it makes. I will make an angled die more like post 8, that will make the tube end stronger and better supported, without the stress riser of the fold.

Two half dies for the centered one.

[Astronowanabe]

Thanks,

That's mostly what I figured, but no mandrel can be used, the pipe will be closed at both ends, which would trap any mandrel.
Naturlich....

Well almost any mandrel... how about frozen water then a pin hole to steam it out