I got most of the parts from Surplus Center to make it easier for anyone following along. My goals were to get the most performance out of a 120v 15 amp outlet I could get and not limit the capacity of my model 32 (bend 2" x .250), keep costs down, limit NPT threads and make packaging small. This meant a 1.5 hp motor and a hydraulic cylinder just long enough to get to the first re-pin. If you would rather have one that made it to 90 degrees before re-pinning, you can just get a longer 2" bore cylinder with the same ports and longer hoses.
First thing I did was call JD Squared and get some information on force required to bend 2" x .250 DOM. While they didn't have an exact pounds of force number for me, they were very helpful and shared some drawings and spec sheets. They use a 1.688 bore cylinder and they said that going over 4000 psi could damage the frame but was plenty to handle the bending. Since I wanted to use a more common, cheap 2" bore cylinder, that meant to get an equivalent ~9000 pounds of force, I only needed 2850 psi. This is important because the pump I chose is capable of peak pressures over 3700 psi. So we must not exceed 2850 psi. There is a relief valve built into the listed directional control valve, pre-set at 2250 psi, which I'm guessing will probably never need to be adjusted for my use.
OK, on with the parts list. Major components:
Motor, 1.5 hp 1800 rpm 110/220v reversible, IronHorse MTR2-1P5-1AB18 -
https://www.automationdirect.com/ad...eneral_purpose/general_purpose/mtr2-1p5-1ab18
0.12 cu in Dynamic GPF1020PC Hydraulic Gear Pump -
0.12 cu in Dynamic GPF1020PC Hydraulic Pump | Gear Pumps | Hydraulic Pumps | Hydraulics | www.surpluscenter.com
Pump mount -
SAE AA 2-Bolt To 56C Thru 145TC Electric Motor To Pump Mount Hydra-Mount Corp E49-AA | Hydra-Mount | Brands | www.surpluscenter.com
Pump side coupler, 1/2" L-075 -
1/2" L-075 Jaw Coupling Half | 3 Piece Flexible Jaw Couplers | Shaft Couplers | Power Transmission | www.surpluscenter.com
Motor side coupler, 5/8" L-075 -
5/8" L-075 Jaw Coupling Half | 3 Piece Flexible Jaw Couplers | Shaft Couplers | Power Transmission | www.surpluscenter.com
Coupling elastomer, open center Lovejoy L-AL 075 (I used the Surplus Center L-075 elastomer, but it didn't have the clearance in the center and i had to modify it to work. This one shoulddrop right in) -
Lovejoy - 68514410626 10626 Size L-AL 075 Open Center Type Jaw Coupling Elastomer, Urethane, 3/4" Open Center, 1.75" OD, 0.44" Length, 135 in-lbs Nominal Torque: Spider Couplings: Amazon.com: Industrial & Scientific
1 Spool 10 GPM Chief 220906 DA Hydraulic Valve -
1 Spool 10 GPM Chief 220906 DA Hydraulic Valve | Directional Control Valves | Hydraulic Valves | Hydraulics | www.surpluscenter.com
2x14x1.25 DA Hydraulic Cylinder Wolverine WWXT2014-S -
2x14x1.25 DA Hydraulic Cylinder Wolverine WWXT2014-S | Double Acting Hydraulic Cylinders | Hydraulic Cylinders | Hydraulics | www.surpluscenter.com
3/4" NPT 20 GPM Return Line Filter Dirty Hand Tools 100116 100448 -
3/4" NPT 20 GPM Return Line Filter Dirty Hand Tools 100116 100448 | New Arrivals | www.surpluscenter.com
5000 PSI 2.5" LF LM Gauge Dynamic CF1P-350-A -
5000 PSI 2.5" LF LM Gauge Dynamic CF1P-350-A | Pressure & Vacuum Gauges | Pressure Gauges | Air & Pneumatics | www.surpluscenter.com
The rest of the parts are basically just fittings and hoses. You will probably need to adjust hose lengths and change elbows to straights and vice-versa to fit your specific bender cart/frame/pedestal. Also, I made my own reservoir to fit within my space constraints, so I am including fittings for that. This list will be in order of how the fluid flows through the system, from reservoir to pump to valve to cylinder, back to the valve, to filter and back into the reservoir.
3/4" NPT Plastic Tank Breather Buyers Products HBF12P -
3/4" NPT Plastic Tank Breather Buyers Products HBF12P | Buyers Products | Brands | www.surpluscenter.com
3/4" NPT Stamped Weld-In Tank Flange Buyers Products FS075 for filling and tank breather -
3/4" NPT Stamped Weld-In Tank Flange Buyers Products FS075 | Weld-in Tank Flanges | Hydraulic Adapters & Fittings | Hydraulics | www.surpluscenter.com
2 each: 1/2" NPT Stamped Weld-In Tank Flange Buyers Products FS050 for supply and return lines -
1/2" NPT Stamped Weld-In Tank Flange Buyers Products FS050 | Weld-in Tank Flanges | Hydraulic Adapters & Fittings | Hydraulics | www.surpluscenter.com
1/2" Hosebarb x 1/2" NPT Male Straight 4404-08-08 Adapter -
1/2" Hosebarb x 1/2" NPT Male Straight 4404-08-08 Adapter | Hosebarb to NPT Male - Straight | Hose Barbs | Hydraulic Adapters & Fittings | Hydraulics | www.surpluscenter.com
Pump supply Hydraulic Hose for Push-on Barbed Fittings, 1/2" ID, 25/32" OD. This could probably purchased elsewhere more efficiently. I only needed 6" but had to buy a minimum of 5 feet. So if anyone local needs 4-1/2 feet, come get it! Any 1/2" ID hose rated for suction and hydraulic fluid should work. -
McMaster-Carr
2 each: 1/2" to 1-1/4" SAE #12 Worm Gear Hose Clamp 1/2" Wide Ideal 5212 -
1/2" to 1-1/4" SAE #12 Worm Gear Hose Clamp 1/2" Wide Ideal 5212 | Hose Clamps | Air Fittings | Air & Pneumatics | www.surpluscenter.com
1/2" Hosebarb x SAE 8 Male 90 Degree Elbow 4601-08-08 Adapter, supply line to pump inlet -
1/2" Hosebarb x SAE 8 Male 90 Degree Elbow 4601-08-08 Adapter | Hosebarb to SAE Male - Right Angle | Hose Barbs | Hydraulic Adapters & Fittings | Hydraulics | www.surpluscenter.com
JIC 6 Male x SAE 6 Male 45 Degree Elbow 6802-06-06 Adapter, pump outlet -
JIC 6 Male x SAE 6 Male 45 Degree Elbow 6802-06-06 Adapter | JIC Male to SAE Male - 45 Degree | JIC to SAE O-ring | Hydraulic Adapters & Fittings | Hydraulics | www.surpluscenter.com
3/8" x 48" JIC 6F Swivel x JIC 6F Swivel SAE 100R16 Hydraulic Hose Assembly 5000 PSI, pump to valve hose -
3/8" x 48" JIC 6F Swivel x JIC 6F Swivel SAE 100R16 Hydraulic Hose Assembly 5000 PSI NRP Jones | Hydraulic Hose Assemblies | Hydraulic Hose and Hose Assemblies | Hydraulics | www.surpluscenter.com
JIC 6 Male x JIC 6 Male x JIC 6 Male Tee 2603-06-06-06 Adapter, Pressure line tee to valve and the pressure gauge -
JIC 6 Male x JIC 6 Male x JIC 6 Male Tee 2603-06-06-06 Adapter | JIC Male - Tee | JIC to JIC | Hydraulic Adapters & Fittings | Hydraulics | www.surpluscenter.com
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