Key Takeaways
- Learn to make precise back-to-back 90-degree bends.
- Use tool markings for accurate measurements.
- Ensure bends are in the same plane for uniformity.
Back-to-Back 90-Degree Bend Overview
Start with the shortest part of the back-to-back 90-degree bend, which is a 12-inch stub. Use a bender with a 5-inch radius. For the first bend, ensure the arrow is aligned with the 7-inch mark. This method involves subtracting the 5-inch radius from the 12-inch stub. Once the arrow is positioned correctly, proceed to make the bend ensuring it reaches exactly 90 degrees.
After completing the first bend, measure 24 inches from the initial bend using a tape measure. Align the star of your bender with the 24-inch mark. It’s crucial to have both bends in the same plane to ensure alignment. Use the bender’s handle as a guide to maintain plane consistency and complete the second 90-degree bend.
Ensure both bends are precisely at 90 degrees by verifying with a level. For cutting, various tools such as the Bosch or Makita mini band saws can cut up to 2.5 inches, and you might find these helpful. These are lightweight, with the Bosch being 8.8 pounds without a battery and the Makita 9.0 pounds with a battery. Additionally, consider utilizing tools like the Klein magnetic nine-inch lighted level for accuracy.
Starting the First 90-Degree Bend
To begin with the first 90-degree bend, you need to focus on the shorter part of the back-to-back bends. In this case, it's the 12-inch stub. Align your bender, which has a 5-inch radius, with the arrow at the 7-inch mark. This measurement accounts for the 12-inch stub minus the 5-inch radius, resulting in the need to place the arrow on the 7-inch line.
Once your setup is accurate, proceed with the bend using your bender tool. It's critical to ensure that the bend achieves a full 90 degrees. Verification of the angle helps prevent misalignment in subsequent steps.
After making the initial bend, transition to the next phase by measuring a distance of 24 inches. Position the star of the bender on this 24-inch mark. The alignment ensures that the next bend is in the same plane, achieving uniformity. By placing both pieces on the ground, the correct plane is easier to maintain.
Remember to make slight adjustments as needed when handling the bender to avoid interference, particularly when working with shorter stubs. Ensure the final measurements reflect an exact 24 inches before making final cuts or refinements.
Measuring and Making the Second Bend
Start by ensuring the first bend is completed accurately. Place the arrow of your bender on the 7-inch mark, which accounts for a 12-inch stub minus the 5-inch bender radius. This creates a clean 90-degree bend. Verify the angle using a level to confirm it's precise at 90 degrees.
Next, measure 24 inches from the end of the first bend. Mark this spot clearly, as it guides the position for the second bend. Align the star of your bender with this 24-inch mark, ensuring it's flat on the ground. Both bends must lie on the same plane, so position your tools and materials accordingly.
When executing the bend, shift slightly to the side if needed to avoid obstruction from the bender's handle. Once bent to 90 degrees, re-confirm both bends using a level for perfect alignment. If satisfied, trim the pipe to ensure the stub measures precisely 24 inches. Clean the cut with a reamer for a polished finish. Your bends should now line up correctly in the same plane.
Cutting and Reaming the Conduit
Cut the conduit precisely at 24 inches using a cutting tool, ensuring the ends are smooth and even. Once cut, use a reamer to clean the inside of the conduit. This removes burrs and sharp edges, which is important for a snug and safe fit.
Consider using a mini band saw for cutting. Brands like Bosch and Makita offer mini band saws with a 2.5-inch cutting capacity. The Bosch unit weighs 8.8 pounds without a battery, while the Makita is 9.0 pounds with a battery. Each of these tools provides excellent handling and performance.
Verify that your cuts are accurate by measuring with a tape measure. After reaming, check that the conduit aligns correctly and the cuts are precise. This helps ensure that the overall bend aligns properly with your project specifications.
Final Assembly and Leveling
To start the final assembly, place the back-to-back 90-degree bend on a flat surface to ensure both bends are aligned correctly. Verify that each bend is at an exact 90 degrees using a level. This alignment ensures proper functionality when installed.
Next, mark 24 inches from the back of each bend using a measuring tape. Utilize the bender's star indicator for precise alignment on your mark. Maintaining the same plane between bends is crucial. This positioning helps avoid any misalignment issues during the assembly.
Trim the conduit to meet the 24-inch requirement. After cutting, use a reamer to smooth the edges, ensuring a clean fit. Once the assembly fits snugly and is level, your back-to-back 90-degree bend is ready for installation. Make sure all connections are secure and aligned appropriately.
Tools and Materials Recommendations
To create a back-to-back 90-degree bend, you'll need a few essential tools:
- EMT Benders: For this task, the Ideal 3/4-inch ductile iron EMT bender is a solid choice. There are also options for 1-inch and 1/2-inch sizes. If you prefer aluminum benders, Ideal offers those as well.
- Mini Band Saws: Consider the Bosch and Makita models, both excellent options with a 2.5-inch cutting capacity. The Bosch weighs 8.8 pounds without a battery, while the Makita weighs 9 pounds with a battery.
- Measuring Tape: Ensure your measurements are precise for accurate bends.
- Reamer: This will help you clean out the interior of your cuts.
- Cline Magnetic 9-Inch Lighted Level: A handy tool for maintaining accuracy and direction. It features a button that lights up the level for easy use in low light conditions.
Each of these tools plays a critical role in achieving precise bends, making the process more efficient and effective. Consider checking the video description for links to recommended products if you're interested.