Tubing roller build

[Brucker]

Yet another shop equipment build. This time, our take on the Harbor Freight/Swag Off Road style tubing roller. We have used the HF roller with some of the upgrades that Swag offers for a number of years already. But during our big shop move a couple years back, the roller setup was damaged. This led to inconsistent rolls and lots of frustration trying to resolve the issues. So here we are finally fixing the issues once and for all while adding our unique spin.

Our original setup:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51473&d=1612943174

Link to HF roller: https://www.harborfreight.com/tubing-roller-99736.html

Link to Swag's roller upgrades: https://www.swagoffroad.com/SWAG-Tubing-Roller-Dies-Accessories_c_54.html

We wanted to keep the new platform similar to the old so that dies could be purchased instead of having to make custom dies. Although we have made a couple custom die sets for it already and will make a few others as well, but more on that later. Another reason to keep it similar was the fact that we still had some unused parts on the shelf from Swag. Specifically, the electric drive kit including the electric threader.

Got started designing in SW:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51488&d=1612981387

Then made all the cutting files needed and cut some pieces out with the plasma table as well as the mill and lathe. Instead of going in depth with each piece being produced, we will just show the finished pieces. If you want more info on how some of the individual pieces were created, here are a couple short videos of 2 of the processes:


https://youtu.be/LQ5VD2WfpqE

[Brucker]

https://youtu.be/a_7RNfiR06g

First up were the main body plates cut out on the plasma. Here there are after being cleaned up:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51491&d=1612981458

Machined a few internally threaded standoffs for the base:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51484&d=1612981337

Machined the pieces needed for the main drive carriage/trolley then assembled them:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51481&d=1612981337

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51466&d=1612943038

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51463&d=1612942967

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51462&d=1612942967

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51498&d=1612981507

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51499&d=1612981507

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51494&d=1612981458

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51471&d=1612943174

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51464&d=1612942967

[Brucker]

Machined the top plate:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51460&d=1612942967

Modified the top spring retainer plate that came with the Swag kit to include a countersunk mounting hole for the top of the bottle jack:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51495&d=1612981507

Return springs:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51468&d=1612943038

Bottle mounting plate for the jack, springs, and the indicator guage:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51493&d=1612981458

Modified a 4 ton bottle jack by drilling and tapping the top and bottom and adding a release knob made by Swag:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51485&d=1612981387

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51492&d=1612981458

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51465&d=1612943038

[Brucker]

Spring retainers for the main shaft that came in the Swag kit:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51489&d=1612981387

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51486&d=1612981387

Welded together and to the main shaft:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51496&d=1612981507

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51501&d=1612981574

Machined a delrin washer for the main shaft:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51476&d=1612943231

Welded together the drive shaft and drive hub from Swag:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51479&d=1612943231

Assembled the roller pins for the non driven dies:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51500&d=1612981574

Cut out an indicator for the gauge/scale setup:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51490&d=1612981458

And cut out the gauge/scale:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51469&d=1612943038

[Brucker]

With all the pieces cut, we can assemble:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51459&d=1612942376

Final product (for now):

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51458&d=1612942376

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51478&d=1612943231

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51505&d=1612987607

Would like to go to a hard stop eventually for easily repeatable rolls, but for now this simple scale should work well. Detail of the scale/gauge setup:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51504&d=1612987607

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51503&d=1612987607

And after the first test piece of 1.75" x .120" wall DOM round tubing:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51482&d=1612981337

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51483&d=1612981337

[Brucker]

We happened to find a few of the "blank" die sets for the roller from HF back during one of their inventory closeouts, so we bought what we could.

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51474&d=1612943174

So those plus some lathe time and we have a few different custom dies along with the standard dies that come. So far we are able to roll 1", 1.5", 1.75", and 2" round tubing. Flat stock up to 1/2" thick and 3" wide, both the easy and hard ways. And a single 1/2" square die, but more will be purchased or made as needed.