Wire Bending 101
 

I am not speaking to simple angle bends here, although, if you have a technique that works well, go ahead and post if you would like to.

Here is a technique that I need to learn. This isn't used in many aircraft today, so a lot of this has become antiquated for most aircraft.

I have plans for plans building a J-Bipe. I need to bend some wire for the cabanes and landing gear.

Why not just purchase a prebent aluminum landing gear??? I want to build it as designed.

I'll upload photos of the plans to show the types of bends and loops I need to make.

Dubro has a nice wire bending tool. The problem I see is that the wires I'm needing to bend are in american measurements, and the sizes the dubro tools say are compatable are all in metric sizes.

Thoughts?

RE: Wire Bending 101
 

So, I stole this picture from another thread in the vintage airplane thread. It shows the types of bending I'll need to be doing.

[link]http://www.rcuniverse.com/forum/m_6413002/mpage_1/key_/tm.htm[/link]

RE: Wire Bending 101
 

Brian, The DuBro should work. How thick is the wire you're bending? I've got one of these you could borrow if you like.

http://www3.towerhobbies.com/cgi-bin...&I=LXGFW4&P=ML

RE: Wire Bending 101
 

Thanks Mike!

I am unsure the wire sizes yet. I just put an order in for the plans at Eureka yesterday. I guess it would help if I knew what I need to work with, wouldnt it! :D

Brian

RE: Wire Bending 101
 

Well, the bender I have will work with wire up to 1/4"

RE: Wire Bending 101
 

Does it make tight bends, like the loops in the picture?

I'll probably just order the tool if it is the tool I need for this job.

(I appreciate the help!)

Brian

RE: Wire Bending 101
 

Ah, you must have posted that as I was making my first post. I didn't see those pics till now.

No, the tightest it will bend is like the loop in a nose gear spring.

RE: Wire Bending 101
 

Brian , I have used 1/8" welding rod for struts & if braced properly are plenty tough for most bipes. This rod is copper coated ,cheap & really nice to work with.If you can find a pair of round nose pliers they will do a pretty good job on the loops if you are strong enough. I also have gone to a electric stove & dryer repair shop & bought their heavy duty wire ends & soldered them on for the wing hold down bolts . Good luck, Max H. :)

RE: Wire Bending 101
 

I use a set of Harry Higley Zee wire bending jigs for anything up to 5/32" or so. With a bit of playing they will form about any shape you need.

For the "BIG" stuff I have a K&S "Mighty Wire" bender that will go up to 1/4" music wire (without shattering the bend - but wear goggles anyway). It will coil wire up to 3/16", so it will form .60 size nose gear.

As an alternative to your bends - I have soldered copper or brass "J" straps (flat strap rolled at one end to fit the wire tightly) on the end of cabane and wing struts drilled for the fasteners rather than try and bend the shape. MUCH easier as you can crimp them in place to set the incidences and then silver solder them after dismounting the wings carefully. Perfect alignment and the fasteners are flush instead of up on the thickness of the wire.

RE: Wire Bending 101
 

Charlie-

That's it!!!!!! This completely solves the problem. Thank you, thank you, thank you! This is exactly how my Pica WACO mounts the top wing on (slightly different mounting precedure though.)

I can't believe I didn't remember this. Is this the idea you're talking about?

RE: Wire Bending 101
 

More or less. I don't have images here at work but I'll post one tonight.

Found one from a build thread -

Here's an image I stole from Jim Dines that shows them. Flat copper battery connectors that loop around the cabanes and are soldered once you're happy with the positioning. I believe they are called "flag lugs" at electrical supply stores.

[img]{akamaiimageforum}/upfiles/26719/Ws56631.jpg[/img]

RE: Wire Bending 101
 

I just wonder...

Could you CA the lugs onto the wire? At least temporarily until you get a chance to solder it?

RE: Wire Bending 101
 

You could, but then you'd have to pull them off, get all the ca off, and then solder.

Thanks for the photo Charlie. I'll look for these.

Brian.

RE: Wire Bending 101
 

I received my plans. I think I'll like this one much more than the Hog Bipe. It is a little smaller. Boy, if this bipe builds to the weight suggested in the plans, I ought to have unlimited verticle it with my Magnum .91 four stroke!

This should make for a sweet classic pattern biplane.

The updated "Firemaster" plans use the same wire connector I posted a pic of instead of the loops on the cabanes.

Brian

RE: Wire Bending 101
 

I have a J-bipe kit sitting in storage waiting for the day I'll build it. I wonder if it has pre-bent cabane wires?

Tom

RE: Wire Bending 101
 

Yes it does!!!! [sm=thumbup.gif]

It probably doesn't have the modifications for the wing struts, headreast, windshield, or prebent dural landing gear that the "Firemaster" updates give you. You can purchans the "Firemaster" version of the plans from Don Turnock at Eureka Aircraft for $25.00.

You can see the difference between the original J-Bipe design and the slight modifications in the pictures below. I think the modifications really add to the looks The only thing I think I will change are the aileron tips. I will glue 1 1/2" piece of aileron stock to the tips of the wings.

I will build mine pretty much stock, other than that. I may want more authority in the rudder, but I'll have to see how it flies with the stock rudder first.

Those strip ailerons ought to be WILD!!!!

I guess most other posts I make on this bipe will be located in the Classic Pattern thread as most everything else will be irrelelavent to this thread. Thank you to everyone that has helped me here.

Brian