Make a Bending Iron

Tough to make wood fit the mold without a side bending tool. My choice in side bending is the hot pipe. I didn’t have one of my own, so I asked Mark Kett how to make one.

My contribution to the science of side bending is figuring out that a BBQ lighter has all the parts you need for a heating element (scavenging electrical heaters and ovens also works, water heater elements do not work).

Here is how you can make your own, only takes about three hours:

Home » By David LaVallee » Lesson » Make a Bending Iron

2. Drill And Tap

You should also connect the green wires (ground). You don’t need to cut the white wire unless you need to thread the cord into a small electrical box (like I did). Carefully connect the wired using twist caps, and electrical tape over that (If you are unsure of your electrical skills).

1. Materials

Home Depot for the lot. The electric barbecue lighter for ten bucks also saved me the six bucks for an electrical cord.1. Lutron 1000W Incandescent Light Dimmer $29
2. Electric BBQ Lighter (500W) $10
3. 16 inches of two inch diameter steel pipe $5
4. 5/16 threaded rod, 12 nuts and washers $5
5. Shop scrap 3/4 inch plywood

I also bought a 5/16 inch tap at the Depot, and drilled four holes in the pipe and tapped them so the threaded rod could screw right in to the pipe.

3. Legs And Base

Cut four pieces of the rod into six to eight inch lengths. Bend them using a metal vise and small sledge hammer so that they are angles to enter the base in a perpendicular fashion. Screw them into the pipe and use a washer and nut to lock the rod to the pipe. Mark and drill holes into the base, then bolt the pipe assembly to the 3/4 inch ply base (nut, washer, plywood, washer, nut).

4. Strengthening Base

Cut four pieces of the rod into six to eight inch lengths. Bend them using a metal vise and small sledge hammer so that they are angles to enter the base in a perpendicular fashion. Screw them into the pipe and use a washer and nut to lock the rod to the pipe. Mark and drill holes into the base, then bolt the pipe assembly to the 3/4 inch ply base (nut, washer, plywood, washer, nut).

5. Wiring

Drill out the rivets and remove the plastic cover of the BBQ Lighter (voiding warranty). Carefully remove the wiring and heating element intact. Take about nine inches of insulation off of the cord. Gently (but firmly) reshape the heating element so that it will fit into the pipe snuggly. Do not damage the inner wires of the cord! The idea here is that you are going to put the dimmer (with its black wires) in line with the black wire of the cord.

6. Dimmer

Anything that you suspect of being a bare wire with 120 volts in it should be carefully insulated with electrical tape (red in this picture).
Note that I built up a platform of plywood so that the electrical box is close to the pipe.

7. Complete Hot Pipe (Side Bending Iron)

There it is. To use it, clamp to a secure bench, plug it in and turn it to high for 10 to 20 minutes (water should instantly boil if dropped on the pipe). Then dial it back half way and try some bending. If the wetted wood scorches, it’s too hot, turn it down. If the wood doesn’t seem to be getting warm (steam should be occasionally visible) turn it up. Mark your sweet spot for next time.

The de Jonge. method of side bending relies on always maintaining a curve, in other words, avoid all sharp bends, they are murder to get out. §