I need to put some 90 degree bends into 2-56 pushrods. What's the best way to bend it? I have been using pliers, but there's gotta be a better way!

F2,

You must be talking about z-bends to connect to a linkage no?? If you are, check out http://www.hobbico.com/tools/hcar2000.html

I don't actually want z bends, just an L...

I personally stay away from the Z-bend pliers. The Z bend pliers put an extremely tight bend in the rod. I have seen two planes crash due to failure at the point where the 2-56 rod is bent (with Z-bend). I would only use Z-bend pliers for smaller piano wire. I personally put a 90 degree bend in the wire with a pair of stout pliers and then use DUB855 fastlink pushrod keepers to hold the wire on the servo.

The Z bend pliers give you a nice looking sharp bend, but the bend is week. The radius of the bend with the pliers is much greater and the bend is much stronger. Some wires bend easier than others.

The chance of failure is remote. I just don't want to chance it. I've seen two nice planes go in.

He said he didnt want to use pliers

Try a vise. Pliers are the best. Z bend "pliers" are possibly an accident waiting to happen. I don't mean needle nose pliers, good stout pliers. With a little practice, 90 degree bends are extremely simple.

I use a vise and hammer. Clamp the wire in the vise at the point you want the bend, making sure it's sticking straight up. Then use a hammer to tap it to 90 degrees. You can also use a piece of hardwood against the wire as close to the vise as possible, and use the hammer on the wood. If you don't have a vise, even a small, cheap one will really come in handy. and I suggest you spring for one. You'll find lots of uses for it. When possible, make your bend and then cut the wire. Try to avoid making a quarter inch bend right at the end of your wire.

I clamp the wire in a vise between two small pieces of soft wood (like scrap pine moulding). I then form the end into an L by tapping with a hammer, or if the end is long enough I bend it by hand.

The wood crushes slightly and allows a small radius to form in the wire, which keeps the bend storng. Sharp bends tend to be weak and can fracture.

The previous post is correct about the sharp bend weakening the wire. I've never had one fail, but the wood sandwich is a great idea. I'll use it from now on unless I've GOT to have a really sharp bend for some reason.

Yep, a 'Z' bend "can" fail, but it has a good track record to stand on!

The new Du-Bro Z bending tool is great and it appears NOT to introduce stress cracks.

No matter if you use a 'z' or an 'L', use SOFT wire, like the .072" threaded rod material.

Jerry

I have an expensvie way of doing it, but I am very good at doing it, if you want to you could give me your plane for a day. All I do is make sure I loose total control of the craft and voila! you've got bent pushrods, except no plane to use them in.
............LOL
Ledz

K&S makes a nice wire bending tool. Small and large tools. Similar to a tubing bender.

Harry Higley makes some fixtures [various sizes] that work very well, they are mounted in your vise to hold the tool only.

Micro-Mark offers some wire benders, these are also capable of bending flat stock and sheet metals.

I got tired of being unable to make L bends when I needed or to make very slight bends maybe 15 degrees whenever it is necessary. I solved both problems buying another set of Z bend pliers and grinding half of the Z away. This leaves a very nice pair of L bending pliers. Think about it. I now have a zig without a zag. Hopes this helps.

Just a word of caution. You said you want to bend 2-56 material. This is a poor practice as the threadied rod (which I assume you are using) is very weak after being bent. If you are talking about bending piano wire of that general diameter, you are okay. I also like the L bends much better than the Z bends when used with the proper atachments (those little plastic clevis like things that lock the Lbend onto the servo arms). They have less slop, are easier to install and easier to make.