Clarke CCB 1, CCB 2, 7630073, 7630074 User guide

METAL BENDER

Model Nos: CCB1 & CCB2

Part Nos: 7630073 & 7630074

CCB2

CCB1

OPERATING & MAINTENANCE

INSTRUCTIONS

1

0708

The Compact Bender allows you to economically make a variety of bends in flat, square, or solid
round stock. These instructions provide basic information on using the Bender, plus step-by-step
examples of how to bend stock to make several common products. We urge you to read the
complete Operation section before trying to use the Bender.

Important Warnings

To protect against serious injury, use common sense and observe the following precautions when
operating the Compact Bender. Clarke International is not responsible for misuse of the Bender.

• ALWAYS secure the Bender to the floor before operating.

• ALWAYS study these instructions before operating, and pay close attention to all warnings.

• ALWAYS keep the work area free of obstructions.

• ALWAYS wear safety goggles when bending parts and when grinding or sanding them.

• ALWAYS be sure that enough material extends beyond the stop block and forming die when making
bends, to be sure the material does not come free and allow the handle to release suddenly.

• ALWAYS insert the hinge pins fully before making bends.

• NEVER try to bend material other than hot-rolled, mild steel.

• NEVER try to bend flat material larger than 5 16 x 2 in., or square or solid round material larger
than 5 8 in. (EXCEPTION: Rebar that is 1/2-in. diameter may be bent around the 3” die only).

• NEVER bend round stock when using the sharp-angle-bend attachment. Use only flat, hot-rolled,
mild steel up to 3/16 x 2” or 1/4 x 1-1/4” with this attachment.

• NEVER try to bend material that is more than 1 4” thick around the centre pin (instead, use the
1” die on the pin).

• NEVER modify the Bender or use a handle extension arm other than the one provided.

Glossary

Assembly ....................................................................................................... 3

General Information .................................................................................... 4

Operations .................................................................................................... 5

Using the Stop Block........................................................................ 5

Using the Sharp-Angle-Bend Attachment ................................... 6

Examples:

Bending Handles ............................................................................. 7

Bending Tube Clamps .................................................................... 8

Bending Anchor Bolts and U-Bolts ................................................. 11

Bending Letters for Signs................................................................. 15

Parts List & Diagram ..................................................................................... 36

2

Assembly

1. To attach the ring assembly to the stand (refer
to the illustration opposite):

a. Attach the loop end of the ring assembly

to the stand. Use the long bolt, flat washer,
thick spacer (inside the loop), thin spacer,
lock washer, and lock nut.

b. Attach the ring end to the stand with the

two flat-head bolts, using thin spacers, flat
washer, lock washers, and lock nuts.

2. Insert the loop end of the handle inside the loop
of the ring assembly, and secure it by inserting
one of the two longer hitch pins.

3. Remove the 'R' clip from the handle pin then
remove the pin from the handle. Pull out the
extension arm, install the pin in the outer hole,
and reinstall the 'R' clip.

4. Set the Bender in the position where you intend
it to be used. Rotate the handle as far as it will
go in both directions, to be sure there will be
no obstructions when bending.

5. Attach the Bender’s base securely to the floor.

3

General Information

Basic Operation

Most of this manual is devoted to showing you how to create basic shapes. Other than these
specific instructions, setting up the Bender to form your particular shape will involve a certain amount
of trial-and-error.

You will notice some differences in operation depending on whether you are forming the piece around
a die, or whether you are making a sharp-angle bend in the piece. However, in general you will:

1. Determine the appropriate material and size for the part(s) to be made.

2. Determine the appropriate dies to install on the centre pin and/or the pin installed in the handle,
and determine the appropriate hole for attaching the handle to the ring assembly’s loop.

3. Install the stop block or the sharp-angle-bend attachment, as appropriate. Install the block
support. If the stop block is used, orient it properly. Refer to pages 4 and 5 for more information
on the stop block and the sharp-angle-bend attachment.

4. Insert the blank stock into the Bender, and position it properly for the first bend.

5. Make the first bend. Re-check the angle and location before continuing.

6. Make any additional bends in the same way. In some cases, you may have to remove the piece
from the Bender and turn it end-for-end or upside-down.

Hole Identification

In the examples shown in this manual, the holes in the loop and
those in the handle are identified by a number. Refer to the
illustration at right.

Measuring Bend Angles

When accuracy is required, you will need a suitable device for
measuring the bend angles.

Fixed and Adjustable Stops

If you are making multiple parts with the same bend angle, using
the same setup (dies and hole locations), the operation will be
speeded up by installing either the fixed or adjustable stop in
the appropriate hole in the ring assembly.

After determining the handle rotation, insert the fixed stop into the
next open hole and use as a guide for bending additional parts.

When greater precision is required, attach the adjustable stop as
accurately as you can at the limit of handle rotation. Make a test part
with scrap material, and reposition the adjustable stop as necessary.
Tighten bolt and nut securely before bending production parts.

Notes

• If precise dimension are required, start by making a test part
using scrap material of the same thickness. Readjust the setup
as necessary.

• Once you determine the dimensions, die size(s), holes, and
bending sequence for a part, write down the information
for future reference.

4

Operation: Using the Stop Block

IMPORTANT: Read page 3 before you proceed to this section.

Purpose of the Stop Block

The stop block prevents the material from rotating while a forming die in
the handle bends the material around either the centre pin or another
die that has been installed on the centre pin.

When you are bending material, the stop block will be located (using a
hitch pin) at one of the five large holes in the middle of the ring assembly’s
loop. (The large hole at the open end of the loop is for the centre pin.) You
will have to determine by trial which hole you will use, depending on the
thickness of the material being bent, the size of the centre-pin die, and the
orientation of the stop block.

Positioning the Stop Block

1. Connect the handle to the centre pin of the loop, with the
appropriate die installed on the centre pin.

2. Install the appropriate die at the appropriate hole in the handle.

3. Inset a piece of the material to be formed. With the
handle all the way back (anticlockwise), install the
stopblock

IMPORTANT: Always use the loop hole that places the stop block
as close to the centre pin or die as possible, while leaving space
for the material to be inserted.

If there is too much space between the stop block and the
centre pin or die, turn the block to a different orientation or
move the block one hole closer to the centre.

Positioning the Block Support

The block support must be located under the stop block as
shown, to keep the block centered vertically in the loop.

Install the support in the appropriate loop hole where it will
support the stop block but not interfere with inserting the hitch
pin all the way through the block hole and the lower hole in
the loop.

Clamping

If the stop block is positioned correctly, the material will
normally not have to be clamped in the Bender. However,
when you are making special bends or need precise
dimensions, it is helpful to clamp the material against the
stop block using a vice-grip pliers as shown at right.

5

Operation: Using the Sharp-Angle-Bend Attachment

IMPORTANT: Read page 4 before you proceed to this section.

Purpose of the Attachment

The sharp-angle-bend attachment is used instead of the stop
block (page 6) when you make a right-angle bend or other
sharp bend in flat material.

Positioning the attachment

In contrast to the stop block, the sharp-angle bend
attachment has only one correct orientation—as shown at
right, and with the hinge pin in the #2 hole in the loop.

Positioning the Block Support

The block support must be located under the sharp-angle­bend attachments, to keep the attachment centered
vertically in the loop. (Compare the illustration on page 4,
with the stop block.)

Install the support in the #3 loop hole, so it will support the
attachment but not interfere with inserting the hitch pin all
the way through the attachment’s hole and the lower hole
in the loop.

Clamping

The material should not need to be clamped when using
the sharp-angle-bend attachment.

Bending the Material

Make thin chalk marks on the flat material to show where
you want to make the bends. For an example, see page 7.

Insert the material into the Bender so that half the width of
the chalk mark shows and the other half is covered by the
bending edge of the attachment.

If you are making two right-angle bends on the same side
of the material, space their chalk marks about 1/8” further
apart than the desired inside dimension after the bend.

6

Example: Bending Handles

Handles from Round Stock

To make a typical handle, using a 9in. length of 3/8in. round stock and two pieces of flat stock:

NOTE: To make other sizes of handles, experiment to find the appropriate die sizes and stop block
orientation.

1. With a long hinge pin, attach the handle and ring loops at their centre-pin holes. Install a 1in.
die on the centre pin.

With the short hinge pin, install a 2 in. die in the handle (#2 hole).

2. With a long hinge pin, install the stop block.

3. Insert the round stock into the Bender so that it extends 2” beyond the centre-pin die (see B),
and make the first bend to 90°.

4. Turn the part end-for-end, position it as in C, and make the second 90° bend. Remove the stock
from the Bender.

5. Drill 5/8” holes in the flat stock, and insert the handle halfway through the holes.

NOTE: Always drill the holes the same size as the diameter of the handle stock.

6. Weld the flat stock pieces in place from the back side. If any weld material extends below the
surface of the flat plate, grind it flush.

Stock required for this example ­One 9in length of 5/8in round
stock.

7

Example: Bending Handles (continued)

Handles from Flat Stock

To make a typical handle, using a 9” length of 3/16” x 1” hot-rolled flat stock:

NOTE: To make other sizes of handles, experiment to find the appropriate bend locations.

1. Install the sharp-angle-bend attachment.

2. Place chalk marks on the material as shown under
“Bend Sequence.” the #1 and #2 marks are
on one face of the material, and the #3 and #4 marks
are on the opposite face.

3. Insert the flat stock into the Bender to the #1 mark
(as in A) and make a 90° bend. Check the angle
before continuing.

4. Set the adjustable stop so each bend will be 90°.

5. Turn the stock end-for-end. Insert it to the #2 mark
(as in B), and make a 90° bend.

6. Turn the stock over front-to-back. Insert it to the #3
mark (as in C), and make a 90° bend.

7. Turn the stock end-for-end. Insert it to the #4 mark

(as in D), and make a 90° bend.

8. Grind and sand all sharp corners.

Stock required for this example ­One 9in length of 3/16in x 1in flat
stock.

Bend Sequence

23

1½”

1½”

4

1½”

1

1½”

8

Example: Bending Tube Clamps

Single-Tube Clamp

To make a 1” I.D. tube clamp (for clamping 1” O.D. tubing), using a 4½” length of 3/16” x 1” hot­rolled flat stock:

NOTE: To make other sizes of clamps, experiment to find the appropriate die sizes and stop block
orientation

1. With a long hinge pin, attach the handle and ring loops at their centre-pin holes. Install a 1” die
on the centre pin.

With the short hinge pin, install a 1½-in. die in the handle (#2 hole).

2. With a long hinge pin, install the stop block.

3. Insert the flat stock into the Bender so that it extends
1½-in. beyond the centre-pin die (as in B below).

Clamp the stock against the stop block using a vice­grip pliers, to prevent the stock from slipping.

4. Make the first bend by pulling the handle around until
the handle die runs off the end of the piece.

.

5. Remove the stop block and the two dies. Change
the handle connection, and install the sharp-angle­bend attachment (as in C below).

6. Insert the stop pin into the 6th hole of the ring
(counting clockwise from the closed end of the

loop).

7. Make the second bend by pulling the handle until it
is about 1/8” from the stop pin.

9

Example: Bending Tube Clamps (continued)

Double-Tube Clamp

To make a 1” I.D. tube clamp (for clamping two lengths of 1” O.D. tubing), using a 4½” length
of 3/ 16” x 1” hot-rolled flat stock:

NOTE: To make other sizes of clamps, experiment to find the appropriate die sizes and stop block
orientation.

1. With a long hinge pin, attach the handle and ring loops at
their centre-pin holes. Install a 1” die on the centre pin.

With the short hinge pin, install a 1½” die in the handle

(#2 hole).

2. With a long hinge pin, install the stop block.

3. Insert the flat stock into the Bender so that it extends 1-3/4”
beyond the centre-pin die (as in B).

4. Make the first bend by pulling the handle around until the
handle die runs off the end of the piece.

5. Reverse the part end-for-end. Insert it into the Bender so that
it extends 1-3/4” beyond the centre-pin die (as in C).

6. Make the second bend by pulling the handle around until
the handle die runs off the end of the piece.

7. Remove the stop block, and install the sharp-angle-bend
attachment.

8. You will have to temporarily remove the centre pin to insert
the piece into the Binder. Slide the piece as far left as
possible, against the centre pin (as in D).

9. Make the third bend by pulling the handle until it is about 1/8”
from the stop pin.

10. Reverse the part end-for-end. Slide the piece as far left as
possible, against the centre pin (as in E). You will again have
to temporarily remove the centre pin to insert the piece

into the Bender.

11. Make the fourth bend by pulling the handle until it is about
1/8” from the fixed stop.

10

Bending Anchor Bolts and U-Bolts

Anchor Bolts

To make a 10” long anchor bolt shown, from a 12¼”
blank:

NOTE: To make another length bolt, just use a shorter
or longer blank, or, change the dimension given in Step
3 below (being sure that enough material is caught by
the block).

1. With a long hinge pin, attach the handle and ring
loops at their centre pin holes. Install a 1” die on
the centre pen.

With the short hinge pin, install a 2” die in the handle
(#2 hole).

2. With a long hinge pin, install the stop block.

3. Insert the bolt blank into the Bender so that the
unthreaded end extends beyond the stop block:

1/2” for 3/8” bolts;

5/8” for ½” bolts;

3/4” for 5/8” bolts.

4. Pull the handle around until the bolt shaft is 90°

from the anchor.

11

Example: Bending Anchor Bolts and U-Bolts (continued)

U-Bolts

The tables on pages 12 and 13 show the appropriate setup for making U-bolts in typical finished
lengths and bend radiuses, from common diameters of round stock.

The illustration below shows the setup for making a U-bolt that is 3½” long and 2” I.D., using 5/8”
diameter stock. For other sizes, adjust the die sizes as shown in the tables.

Length

For longer U-bolts, add twice the additional length desired to the “blank length” indicated (for
example, to make a U-bolt that is 1” longer, add 2” to the blank length).

Bend Radius

Eight bend radiuses are possible—by selecting from the seven forming dies, or by using centre pin
without a die. However to avoid bending the centre pin, always use a forming die with round stock
larger than 3/8” diameter.

Notes

• Because blank stock may vary slightly in content or size, we recommend making a test bend
using unthreaded stock before you make a quantity of U-bolts.

• Keep a record of die sizes, die positions, and other measurements for future reference.

12

Example: Bending Anchor Bolts and U-Bolts (continued)

Bending U-Bolts from 1/4” Round Stock

FINISHED SIZE SETUP FOR BENDING

Blank Loop Stop Block Centre Handle Handle

Length I.D. Length Hole No. Meas’t Pin Die Die Hole No.

2" 1" 5" 1 Flush 1" 2" 2

2-1/4" 1-1/4" 5-1/4" 1 1/4" 1-1/4" 2" 2

2-1/2" 1-1/2" 6-3/8" 1 3/8" 1-1/2" 2" 2

3" 1-3/4" 7-1/2" 2 1/4" 1-1/4" 2" 2

3-1/2" 2" 8-5/8" 2 7/8" 2" 1-3/4" 2

Bending U-Bolts from 1/4” Round Stock

FINISHED SIZE SETUP FOR BENDING

Blank Loop Stop Block Centre Handle Handle

Length I.D. Length Hole No. Meas’t Pin Die Die Hole No.

2-1/2" 1-1/4" 6-1/4" 1 5/16" 1-1/4" 2" 2

3" 1-1/2" 7-3/8" 2 1/4" 1-1/2" 2" 2

3" 1-3/4" 7-5/8" 2 3/8" 1-3/4" 2" 2

3-1/2" 2" 8-3/4" 2 15/16" 2" 2" 2

Bending U-Bolts from 3/8” Round Stock

FINISHED SIZE SETUP FOR BENDING

Blank Loop Stop Block Centre Handle Handle

Length I.D. Length Hole No. Meas’t Pin Die Die Hole No.

2-1/2" 1-1/4" 6-1/2" 1 5/8" 1-1/4" 2" 2

3" 1-1/2" 7-1/2" 2 7/16" 1-1/2" 3" 3

3" 1-3/4" 7-3/4" 2 9/16" 1-3/4" 3" 3

3" 2" 8" 2 1/8” 2" 3" 3

13

Example: Bending Anchor Bolts and U-Bolts (continued)

Bending U-Bolts from 1/2-in. Round Stock

FINISHED SIZE SETUP FOR BENDING

Blank Loop Stop Block Centre Handle Handle

Length I.D. Length Hole No. Meas’t Pin Die Die Hole No.

2-3/4" 1-1/2" 7-1/4" 2 7/16" 1-1/2" 3" 3

3" 1-3/4" 8" 2 15/16" 1-3/4" 3" 3

3-1/4" 2" 8-3/4" 2 3/4" 2" 2-1/2" 3

4" 2-1/2" 10-1/8" 2 1" 2-1/2" 2" 3

4-1/2" 3" 11-5/8" 3 1" 3" 2" 3

Bending U-Bolts from 5/8” Round Stock

FINISHED SIZE SETUP FOR BENDING

Blank Loop Stop Block Centre Handle Handle

Length I.D. Length Hole No. Meas’t Pin Die Die Hole No.

3-1/2" 2" 9-1/4" 2 1" 2" 3" 3

2-1/2" 2-1/2" 11-1/2" 2 1-5/8" 2-1/2" 2" 3

5" 3" 12-3/4" 3 1-7/8" 3" 2" 3

14

Example: Bending Letters for Signs

The following pages show how to make all 26 letters of the
alphabet, in a typical style. Using the procedure that is shown on
these pages results in letters (from 3/16” flat stock) which are:

• 6” high

• 2” wide (deep)

Notes

• Use only hot-rolled mild steel for forming the letters.

• Follow the bending steps exactly, and in the sequence given.
This is especially important for the letter “S”, which is the most
difficult to form.

• To avoid wasting material, practice some of the letters using

3/ 16” stock that is only 1/2” wide before you attempt the
finished version.

• If you have two or more identical letters, make all of them

before proceeding to a different letter.

15

Example: Bending Letters for Signs (continued)

STOCK REQUIRED

3/16” stock; 2” max. width

One 14” blank

One 3-1/2” blank

Setup

Make chalk marks on the 14” blank as shown on the “Bend Sequence.”

Bend No. 1

Insert the stock into the Bender to the #1 chalk mark (as in A), and bend it to 76°. Re-check the angle
before you go on to the second bend.

Bend No. 2

Slide the stock to the #2 chalk mark (as in B), and bend it to 76°. Re-check the angle.

To remove the part from the Bender, remove the pin that holds the sharp-angle-bend attachment.

Finishing

Tack-weld the 3-1/2”. insert piece between the legs of the “A,” parallel to the top edge.

Grind and sand all sharp corners.

16

Example: Bending Letters for Signs (continued)

STOCK REQUIRED

3/16” stock; 2” max. Width

Setup

Make chalk marks on the two 8-7/8” blanks as shown on the “Bend Sequence.”

Bend No. 1

Insert one of the blanks into the Bender to the #1 chalk mark (as in A), and bend it to 45°. Re­check the angle before you go on to the second bend.

Chalk-mark the ring, or set a stop, for ease of repeating the 45° bend.

Bend No. 2

Slide the stock to the #2 chalk mark (as in B), and bend it to 45°. Re-check the angle.

Bend No. 3

Reverse the stock end-for-end. Slide it to the #3 chalk mark
(as in C), and bend it to 45°. Re-check the angle.

Bend No. 4

Again reverse the stock end-for-end. Move it to the #4 chalk
mark (as in D), and bend it to 45°. Re-check the angle.

To remove the part from the Bender, remove the pin that
holds the sharp-angle-bend attachment.

Finishing

Tack-weld the two loops together. Tack-weld the 6 in. piece
to form the back of the letter “B”.

Grind and sand all sharp corners.

17

Example: Bending Letters for Signs (continued)

Setup

Make chalk marks on the 14” blank as shown on the “Bend Sequence.”

Bend No. 1

Insert the stock into the Bender to the #1 chalk mark (as in A), and
bend it to 45°. Re-check the angle before you go on to the second bend.

Bend No. 2

Slide the stock to the #2 chalk mark (as in B), and bend it to 45°.

Re-check the angle.

Bend No. 3

Slide the stock to the #3 chalk mark (as in C),
and bend it to 45°. Re-check the angle.

Finishing

Reverse the stock end-for-end. Slide it to the
#4 chalk mark (as in D), and bend it to 45°.
Re-check the angle.

(continued on next page)

18

Example: Bending Letters for Signs (continued)

Bend No. 5

Slide the stock to the #5 chalk mark (as in E), and bend it to 45°. Re­check the angle.

Bend No. 6

Slide the stock to the #6 chalk mark (as in F), and bend it to 45°.

Re-check the angle.

To remove the part from the Bender, remove the pin that holds the
sharp-angle-bend attachment.

Finishing

Grind and sand all sharp corners.

Setup

Make chalk marks on the two 12-7/8” blank as shown on the “Bend Sequence.”

(continued on next page)

19

Example: Bending Letters for Signs (continued)

Bend No. 1

Insert the blank into the Bender to the #1 chalk mark (as
in A), and bend it to 45°. Re-check the angle before you
go on to the second bend.

Chalk-mark the ring, or set a stop, for ease of repeating
the 45° bend.

Bend No. 2

Slide the stock to the #2 chalk mark (as in B), and bend it
to 45°.

Re-check the angle.

Remove the blank from the Bender. Re-check that the
bend leg is at 90° to the front of the “D”.

Bend No. 3

Reverse the stock end-for-end. Slide it to the #3 chalk
mark (as in C), and bend it to 45°. Re-check the angle.

Bend No. 4

Slide the stock to the #4 chalk mark (as in D), and bend
it to 45°.

Re-check the angle. Re-check that the two legs are
parallel.

To remove the part from the Bender, remove the pin
that holds the sharp-angle-bend attachment.

Finishing

Tack-weld the 6 in. piece to form the back of the letter
“D”.

Grind and sand all sharp corners.

20

Example: Bending Letters for Signs (continued)

Setup

Make chalk marks on the 14-9/16” blank as shown on the
“Bend Sequence.”

Bend No. 1

Insert the blank into the Bender to the #1 chalk mark (as in
A), and bend it to 45°. Re-check the angle before you go
on to the second bend.

Bend No. 2

Slide the stock to the #2 chalk mark (as in B), and bend it
to 90°. Re-check the angle.

Bend No. 3

Reverse the stock end-for-end. Slide it to the #3 chalk
mark (as in C), and bend it to 45°. Re-check the angle.

Bend No. 4

Slide the stock to the #4 chalk mark (as in D), and bend it
to 90°. Re-check the angle. Check that the top and
bottom of the “E” are parallel.
To remove the part from the Bender, remove the pin that
holds the sharp-angle-bend attachment.

Finishing

Tack-weld the 3-1/2” insert piece between the legs
of the “A,” parallel to the top edge.
Grind and sand all sharp corners.

21

Example: Bending Letters for Signs (continued)

Setup

Make a letter “L” as shown on page 24.

Finishing

Position the 2-1/2”. piece as shown and tack-weld it.
Grind and sand all sharp corners.

Setup

Make a letter “C” as shown on page 17.

Bend

Insert the 3” blank into the Bender to the chalk mark, and bend
it to 90°. Re-check the angle.
To remove the part from the Bender, remove the pin that holds
the sharp-angle-bend attachment.

Finishing

Position the 3” piece as shown and tack-weld it.
Grind and sand all sharp corners.

22

Example: Bending Letters for Signs (continued)

Setup

None.

Finishing

Tack-weld the pieces together as shown.
Re-check that the pieces are at 90°
angles to each other.
Grind and sand all sharp corners.

Setup

Make chalk marks on the 5” blanks as shown on the “Bend Sequence.”

Bend No. 1

Insert the blank into the Bender to the #1 chalk mark, and bend it to 45°. Re­check the angle.
Chalk mark the ring, or set a stop, for ease of repeating the 45° bend.

Bend No. 2

Reverse the stock end-for-end. Slide it to the #2 chalk mark, and bend it to 45°.
Re-check the angle.
To remove the part from the Bender, remove the pin that holds the sharp-angle­bend attachment.

Finishing

Position the 5-5/8” piece between
the bent pieces as shown and tack­weld it. Re-check that the parts are
90°.
Grind and sand all sharp corners.

23

Example: Bending Letters for Signs (continued)

Setup

Make chalk marks on the blanks as shown on the “Bend Sequence.”

Bend No. 1

Insert the blank into the Bender to the #1 chalk mark, (as in A), and bend it to 45°. Re-check the
angle before you go on to the second bend.
Chalk mark the ring, or set a stop, for ease of repeating the 45° bend.

Bend No. 2

Slide the stock to the #2 chalk mark (as in B), and bend it to 45°. Re-check the angle.

Bend No. 3

Slide the stock to the #3 chalk mark (as in C), and bend it to 45°. Re-check the angle.
To remove the part from the Bender, remove the pin that holds the sharp-angle-bend attachment.

Finishing

Grind and sand all sharp corners.

24

Example: Bending Letters for Signs (continued)

Setup

Make chalk marks on the 7” blanks as shown on the “Bend Sequence.”

Bend

Insert the blank into the Bender to the
chalk mark, and bend until it measures 6
in. as shown.

Finishing

Tack-weld the pieces together as shown.
Re-check that the outer tips of the bent
piece are equal distances from the
straight piece.
Grind and sand all sharp corners.

Setup

Make chalk marks on the blanks as shown on the “Bend Sequence.”

Bend No. 1

Insert the blank into the Bender to the #1 chalk mark, and bend it to 45°. Re-check the angle.

Bend No. 2

Slide the stock to the #2 chalk
mark, and bend to 90°.
Re-check the angle.
To remove the part from the
Bender, remove the pin that
holds the sharp-angle-bend
attachment.

Finishing

Grind and sand all sharp
corners.

25

Example: Bending Letters for Signs (continued)

STOCK REQUIRED:

3/16” STOCK; 2” MAX WIDTH

2 X 13-1/2” Blanks

Setup

Make two letter “V”s as shown on page 32.

Finishing

Turn the “V”s upside-down, and tack-weld them together as shown. Check that the three bottom
tips are aligned.
Grind and sand all sharp corners.

Setup

Make chalk marks on the 8-1/16” blanks as shown on the
“Bend Sequence.”

Bend No. 1

Insert the blank into the Bender to the #1 chalk mark, (as
in A), and bend it to 73°. Re-check the angle.

Bend No. 2

Reverse the stock end-for-end. Slide it to the #2 chalk
mark, and bend it to 73°. Re-check the angle.
To remove the part from the Bender,
remove the pin
that holds the sharp-angle-bend
attachment.

Finishing

Tack-weld the pieces together. Re­check that
the straight legs are parallel.
Grind and sand all sharp corners.

26

Example: Bending Letters for Signs (continued)

STOCK REQUIRED:

3/16” STOCK; 2” MAX WIDTH

1 X 14” Blank

1 x 3-7/8” Blank

Setup

Make a letter “C” from the 14” blank as shown
on page 17.

Finishing

Tack-weld the two pieces together as shown.
Grind and sand all sharp corners.

STOCK REQUIRED:

3/16” STOCK; 2” MAX WIDTH

1 X 8-7/8” Blank

1 x 6” Blank

Setup

Make part of a letter “B” (page16)—the straight piece and one loop.

Finishing

Tack-weld the pieces together.
Grind and sand all sharp corners.

STOCK REQUIRED:

3/16” STOCK; 2” MAX WIDTH

1 X 14” Blank

1 x 3-7/8” Blank

1 x 2” Blank

1 x 3/4” Blank

Setup

Make a letter “O” (above).

Finishing

Tack-weld the short pieces to the “O” as shown above.
Grind and sand all sharp corners.

27

Example: Bending Letters for Signs (continued)

STOCK REQUIRED:

3/16” STOCK; 2” MAX WIDTH

1 X 8-7/8” Blank

1 x 6” Blank

1 x 3-1/8” Blank

Setup

Make part of a letter “P” (page 26).

Finishing

Tack-weld the 3-1/8” piece to the “P” as shown.
Grind and sand all sharp corners.

Setup

Make chalk marks on the blank as shown on the “Bend
Sequence.” Note that the five chalk marks on one end of
the blank must be on the opposite face from the five marks
on the other end.

Bend No. 1

(continued on next page)

28

Example: Bending Letters for Signs (continued)

Insert the blank into the Bender to the #1 chalk mark (as in A), and bend it to
45°. Re-check the angle.
Chalk-mark the ring, or set a stop, for ease of repeating the 45° bend. (Note
that Bends #3 and #7 are to 41°.)

Bend No. 2

Slide the blank to the #2 chalk mark (as in B), and bend it to 45°.

CAUTION: Because of the number of bends, it is especially
important to check all bend angles carefully when making the
letter “S.”

Bend No. 3

Slide the blank to the #3 chalk mark (as in C),
and bend it to 41°. Re-check the angle.

Bend No. 4

Slide the blank back to the #4 chalk mark (as in
D), and bend it to 45°.

Bend No. 5

Reverse the stock end-for-end. Slide the blank
to the #5 chalk mark (as in E), and bend it to
45°. Re-check the angle.

29

Example: Bending Letters for Signs (continued)

Bend No. 6

Slide the blank back to the #6 chalk mark (as in F), and
bend it to 45°. Re-check the angle.

(continued on next page)

Bend No. 7

Slide the blank to the #7 chalk mark (as in G), and bend
it to 41°. Re-check the angle.

Bend No. 8

Slide the blank back to the #8 chalk mark (as in H), and
bend it to 45°. Re-check the angle.

Bend No. 9

Reverse the stock end-for-end. Pull the pin in the sharp­angle-bend attachment to allow space for the blank.
Insert the blank, and reinstall the pin.
Slide the blank to the #9 chalk mark (as in I), and bend it
to 45°. Re-check the angle.

30

Example: Bending Letters for Signs (continued)

STOCK REQUIRED:

3/16” STOCK; 2” MAX WIDTH

1 x 6” Blank

1 X 5-1/16” Blank

Bend No. 10

Again reverse the stock end-for-end. Slide the blank to the #10 chalk mark (as in J), and bend it to
45°. Re-check the angle, and check that the top and bottom of the “S” are parallel.

Setup

Make chalk marks on the 5-13/16” blank as shown on the “Bend Sequence.”

Bend No. 1

Insert the blank into the Bender
to the #1 chalk mark
(as in A), and bend it to 45°. Re­check the angle.
Chalk mark the ring, or set a
stop, for ease of
repeating the 45° bend.

Bend No. 2

Reverse the stock end-for­end. Slide it
to the #2 chalk mark (as in B),
and

bend it to 45°. Re-check the angle.

Finishing

31

Example: Bending Letters for Signs (continued)

Grind and sand all sharp corners.

Setup

Make chalk marks on the blank as shown on the “Bend Sequence.”

(continued on next page).

Bend No. 1

Insert the blank into the Bender to the #1 chalk mark, (as in A), and
bend it to 45°. Re-check the angle.
Chalk-mark the ring, or set a stop, for ease of repeating the 45° bend.

Bend No. 2

Slide the blank to the #2 chalk mark (as in B), and bend it to 45°. Re­check the angle.

Bend No. 3

Reverse the stock end-for-end. Slide it to the #3 chalk mark (as in C),
and bend it to 45°. Re-check the angle.

Bend No. 4

32

Example: Bending Letters for Signs (continued)

STOCK REQUIRED:

3/16” STOCK; 2” MAX WIDTH

1 x 13-1/2” Blank

Slide the stock to the #4 chalk mark (as in D), and bend it to 45. Re-check the angle, and check
that the legs of the “U” are parallel.

Finishing

Grind and sand all sharp corners.

Setup

Make chalk marks on the 5-13/16-in. blank as shown on the “Bend Sequence.”

Bend No. 1

Insert the blank into the Bender to the #1 chalk mark
(as in A), and bend it to 75°.

Bend No. 2

33

Example: Bending Letters for Signs (continued)

STOCK REQUIRED:

3/16” STOCK; 2” MAX WIDTH

2 x 13-1/2” Blanks

Slide the blank to the #2 chalk mark (as in B), and bend it to 75°. To remove the part, pull the pin in
the sharp-angle-bend attachment.

STOCK REQUIRED:

3/16” STOCK; 2” MAX WIDTH

2 x 7-1/2” Blanks

Finishing

Grind and sand all sharp corners.

Make the letter “W” by tack-welding together two letter “V”s (the same as
a letter “M”—page 26).

Setup

Make chalk marks on the blank as shown on the
“Bend Sequence.”

Bend

Insert the blank into the Bender to the chalk mark, and

STOCK REQUIRED:

3/16” STOCK; 2” MAX WIDTH

1 x 9-1/2” Blank

1 x 3-3/4” Blank

bend it until the outside dimension is 6 in. (as
shown).

Finishing

34

Example: Bending Letters for Signs (continued)

Tack-weld the two pieces together. Check that the
parts are parallel.
Grind and sand all sharp corners.

Setup

Make chalk marks on the blank as shown on the “Bend Sequence.”

(continued on next page)

Bend No. 1

Insert the blank into the Bender to the #1 chalk mark
(as in A), and bend it to 80°. Re-check the angle.

Bend No. 2

STOCK REQUIRED:

3/16” STOCK; 2” MAX WIDTH

2 x 7-1/2” Blanks

Slide the stock to the #2 chalk
mark (as in B), and
bend it to 80°. Re-check the
angle.

To remove the part, pull the pin from the
sharp-angle-bend attachment.

Finishing

Grind and sand all sharp corners.

Setup

Make chalk marks on the
7-1/2” blank as shown on
the “Bend Sequence.”

Bend No. 1

Insert the blank into the
Bender to the #1 chalk
mark (as in A), and bend it
to 50°. Re-check the
angle.

Bend No. 2

Reverse the part end-for­end. Slide it to the #2 chalk
mark (as in B), and bend it
to 50°.

35

Parts List

Item Description Qty Part No:

1 Spacer, loop 1 CCB201

2 Bolt, 3 8 x 41 8-in 1 CCB202

3 Washer, flat, 3 8-in. 4 CCB203

4 Ring assembly 1 CCB204

5 Bolt, flat-head, 3 8-in 2 CCB205

6 Spacer, ring 3 CCB206

7 Washer, lock, 3 8-in. 4 CCB207

PARTS & SERVICE CONTACTS

For Spare Parts and Service, please contact your nearest dealer,

or CLARKE International, on one of the following numbers.

PARTS & SERVICE TEL: [phone]

PARTS & SERVICE FAX: [phone]

or e-mail as follows:

PARTS: [e-mail]

SERVICE: [e-mail]

36