Help ..... Bending Bailey caravan awning rail 25 degrees or so

[Dapph2]

I have a metre of 2009 Bailey Ranger awning rail to replace a wrecked bit .
do any of you know how or where to find out how to bend it to fit the angle whilst keeping the base that 's on the carpet flat ( like an old English hockey stick ) ?

I made a wooden jig for the first one but it wasn't much good as it kept twisting and never managed to get it flat
I thinking of perhaps needing to make some 500mm long plastic & round bar inserts to pack the profile out then fit it into a straight square tube and use my hydraulic pipe bender to gently push it into shape .

 

[waddycall]

It’s going to depend on the radius you need. Got a pic of the old bit?

 

[dave h 2]

Did you give the metal time to flow or just bent it as fast as it would go?
How do you get it out of the square tube after its bent?

 

[Dapph2]

Did you give the metal time to flow or just bent it as fast as it would go?
How do you get it out of the square tube after its bent?

Carefully cut the square tube where there is no aluminium

Did you give the metal time to flow or just bent it as fast as it would go?
How do you get it out of the square tube after its bent?

I took a long time gently trying to push it to the stops on the wooden jig ., but as you can see the base side is going to be difficult .
.

 

[Windy Miller]

…
How do you get it out of the square tube after its bent?

That’s a VERY good question!

 

[Dapph2]

That’s a VERY good question!

Look to my earlier reply