Pittsburgh 31980 User manual

COMPACT BENDER
31980
ASSEMBLY INSTRUCTIONS & PROJECT IDEAS
2000
i sburgh®
Rev 08/00

THANK YOU for choosing a HARBOR FREIGHT TOOLS product. For future reference, please complete the
owner’s record below:
Model___________ Serial No._____________ Purchase Date_____________
Save This Manual
You will need the manual for the safety warnings and precautions, assembly instructions, operating
and maintenance procedures, parts list and diagram. Keep your invoice with this manual. Write the
invoice number on the inside of the front cover. Keep the manual and invoice in a safe and dry place
for future reference.
Technical Specifications
Tool Name:Compact Bender
Item Number: 31980
Dimensions: 10-1/8” W x 39-3/4”H x 35-3/4”L
Stand: .325” Steel
Mounting Holes: (4) ½”
Max. Width of Stock: 1-15/16”
Max. Stock Thickness: 5/16”
Max. Bar Stock Diameter: 5/8”
Dies: 1”, 1-1/4”, 1-1/2”, 1-3/4”, 2”, 2-1/2”, 3”
Tool Weight: 44 LBS.
Safety Warnings and Precautions
WARNING: When using tool, basic safety precautions should
always be followed to reduce the risk of personal injury and
damage to equipment.
Read all instructions before using this product!
1. Avoid working alone. If an accident happens, an assistant can bring help.
2. Keep work area clean. Cluttered areas invite injuries.
3. Observe work area conditions. Keep work area well lighted.
4. Keep children away. Children must never be allowed in the work area. Do not let them handle
machines, tools, or extension cords.
5. Store idle equipment. When not in use, tools must be stored in a dry location to inhibit rust. Always lock
up tools and keep out of reach of children.
6. Dress properly. Do not wear loose clothing or jewelry as they can be caught in moving parts. Protective,
electrically nonconductive clothes and nonskid footwear are recommended when working. Wear
restrictive hair covering to contain long hair.
7. Use eye and ear protection. Always wear ANSI approved impact safety goggles.
8. Do not overreach. Keep proper footing and balance at all times.
#31980 Page 2

9. Use the right tool for the job. Do not attempt to force a small tool or attachment to do the work of a
larger industrial tool. There are certain applications for which this tool was designed. Do not modify this
tool and do not use this tool for a purpose for which it was not intended.
10. Stay alert. Watch what you are doing, use common sense. Do not operate any tool when you are tired.
11. Check for damaged parts. Before using any tool, any part that appears damaged should be carefully
checked to determine that it will operate properly and perform its intended function. Check for alignment
and binding of moving parts; any broken parts or mounting fixtures; and any other condition that may
affect proper operation. Any part that is damaged should be properly repaired or replaced by a qualified
technician. Do not use the tool if any switch does not turn On and Off properly.
12. Replacement parts and accessories. When servicing, use only identical replacement parts. Use of any
other parts will void the warranty. Only use accessories intended for use with this tool. Approved
accessories are available from Harbor Freight Tools.
13. Do not operate tool if under the influence of alcohol or drugs. Read warning labels on prescriptions to
determine if your judgment or reflexes are impaired while taking drugs. If there is any doubt, do not operate
the tool.
14. Maintenance. For your safety, maintenance should be performed regularly by a qualified technician.
Warning: The warnings, cautions, and instructions discussed in this instruction manual cannot
cover all possible conditions and situations that may occur. It must be understood by the operator that
common sense and caution are factors which cannot be built into this product, but must be supplied by
the operator.
WARNING: WELDING PRECAUTIONS
If you perform any welding using the materials that have been bent by this tool, it is important that you
remember that there are additional safety precautions that must be taken. Of course, you should follow
all warnings and instructions provided by the manufacturer of the welding equipment used.
Be aware of flying sparks. Only weld in an area that does not contain any materials which can be ignited by
flying sparks. Extinguish any significant flying sparks before continuing to weld.
Protect yourself and others around you from burns which can be caused by flying sparks.
Make certain that you have a fire extinguisher accessible.
Never weld in an atmosphere which might contain flammable fumes.
Periodically during welding, and after completion of a job, inspect your area for any ignition which may have
been caused by flying sparks.
Never leave your welder unattended while it is plugged in.
Always wear electrical insulating clothing, gloves and shoes while using your welder.
Flying sparks can cause injury, and hot materials can cause burns. Please wear appropriate safety clothing,
and observe precautions to prevent burns or injury to yourself or others.
Wear protective clothing such as heavy gloves, apron and boots.
Do not look directly into the welding arc without appropriate protective eye shields.
Do not allow others to look directly into the arc without appropriate eye protection.
Wear protective gloves while welding. Welding causes the metal to become very hot, which can cause burns.
Do not touch welded areas until you are certain they have completely cooled.
Do not place weld materials where others can touch them, or where they can cause a fire.
#31980 Page 3

WARNING: WELDING PRECAUTIONS (Continued)
The electrode, and especially the welding rods become very hot during welding. Exercise extreme caution to
prevent burns to yourself or others.
NOTE: Read and adhere to all warnings and instructions in the instruction manual provided by the
manufacturer of the welder being used.
Assembly
Your Compact Bender will require complete assembly prior to operation. It is important that you read the entire
manual to become familiar with the unit BEFORE you use the Compact Bender. Before assembling your
Compact Bender be sure that you have all parts described in the Parts List on page 9.
When assembling your Compact Bender, it will be helpful to refer to each of the operational Figures as well as
to the Parts List and Assembly Diagrams on pages 9-11.
Mounting Surface: The mounting surface must be flat, level and capable of supporting the weight of the
Compact Bender combined with the materials to be worked with.
Step 1) Bolt the Stand (#11) to a flat, stable floor surface that is capable of supporting
the weight of this tool and the various workpieces to be used.
Step 2) Place the three (3) Mounting Spacers (#13) over each hole on the top of the Stand (#11)-see
Figure 1.
Mounting
Figure 1-Assembly
Step 3) Place the Ring Assembly/Die Receiver (#10) over the three Mounting Spacers (#13) so that
the two holes on the Ring Assembly (#10) line up with the corresponding Mounting Spacers
(#13). Insert two (2) Mounting Bolts (#16) through the Ring Assembly (#10), Mounting Spacer
(#13) and Stand (#11). Tighten on Nuts (#14)-see Figure 1.
#31980 Page 4

Step 4) Place the Ring Assembly Spacer (#6) inside the arms of the Ring Assembly/Die Receiver
(#10) between the back two holes-see Figure 1. Insert the Mounting Bolt (#15) through the
Ring Assembly/Die Receiver (#10), through the Ring Assembly Spacer (#6) and through the
bottom hole in the Ring Assembly/Die Receiver. Tighten it into place with the remaining Nut
(#14).
Step 5) The Inner Handle (#8) slides into the Outer Handle/ Die Receiver (#9) and is held in place by a
Handle Pin and Hair Clip (#12). The Inner Handle (#8) can be fully extended by pulling out
the Handle Pin and Hair Clip (#12) and pulling out the Inner Handle until the hole in the Outer
Handle (#9) lines up with the holes at the end of the Inner Handle (#8).
Step 6) Place the Outer Handle Die Receiver (#9) between the Die Receiver (#10) and secure it in place
using one of the Long Hitch Pins (#1).
Basic Operation
Following are instructions on the primary uses of your Compact Bender. Additionally, information is included
on the many ways to use your Compact Bender, along with specific examples. Becoming familiar with the
Compact Bender and its many uses will allow you to make a variety of useful items.
As the operator, you will have to decide on the way in which you will be using your Compact Bender. The
following are the basic steps you will need to take when working with the Compact Bender.
Use an appropriate measuring device to measure and:
• Decide on material and measurements to be used.
• Decide on the appropriate Die. Decide on the best placement of the Die for your particular bend.
• Decide on the appropriate attachment, Stop Block or Right Angle Bend. Correct orientation of Stop Block.
• Insert stock into the Bender and position it properly. Make the first bend.
• Check the angle and direction of the bend.
• Make all consequent bends. Adjust the workpiece as needed.
Figure 2-Assemble Handle
Ring Assembly/Die Receiver (#10)
Long Hitch Pin (#1)
#31980 Page 5
Outer Handle/Die Receiver (#9)
Inner Handle (#8)
not shown
Warning: Keep fingers and hands away from moving parts at all times.

How the Holes Are Numbered
Throughout this manual, the holes are often identified by a specific number, i.e., the 3rd hole in
the Handle. There are five (5) holes referred to in the Outer Handle/Die Receiver (#9) and
5 holes referred to in the Ring Assembly (#10). For clarification of each hole and its
corresponding number, please refer to Figure 3 below.
Use of the Support Pin with the Square Stop Block
Step 1) Place the Support Pin (#5) into the hole under the Square Stop Block (#3) so that the Square
Stop Block (#3) will sit correctly in relation to the Ring Assembly/ Die Receiver-see Figure 4.
Step 2) Insert the Support Pin (#5) in the hole so that it sits under the Stop Block but does not block
the Long Hitch Pin (#1) from going through the hole in the Stop Block and into the lower hole
in the Ring Assembly (#10).
If the Stop Block is correctly placed you should not have to clamp the workpiece into place. When working with
exacting bends, however, it may be helpful to clamp the workpiece into place using vise-grip pliers.
#31980 Page 6
12345
12345
Center Point
Outer Handle (#9)
Ring Assembly (#10)
Figure 3 - Numbering of Holes
Long Hitch Pin (#1)
Support Pin (#5)
Square Stop Block (#3)
Figure 4

Placement of Die
Dies are placed at one or two different locations depending on the bend to be made:
• A die can be used in conjunction with the Short Hitch Pin (#2) at the intersection of the Outer Handle/Die
Receiver (#9) and the Ring Assembly/Die Receiver (#10).
• The Die can also be placed on the Outer Handle/Die Receiver (#9).
• Two Dies can be placed so that one is on the Outer Handle/Die Receiver (#9) and one at the center point
where the Outer Handle/Die Receiver (#9) and Ring Assembly/Die Receiver (#10) intersect-see Figure 3.
Orientation of the Handle
The Handle is always oriented up and on the right side. The Handle is always moved clockwise
when a bend is being made.
Use of the Square Stop Block
The Stop Block is so named because it stops the workpiece from turning while the workpiece is being bent,
thus “stopping” movement of the workpiece.
When bending your workpiece, place the Square Stop Block (#3) over one of the holes in the Ring Assembly/
Die Receiver (#10). You will have to do some testing to determine placement of the Square Stop Block. You
will need to place it over the appropriate hole for the bend you desire and the Die you are using.
Step 1) There are four (4) key positions to place the Square Stop Block (#3) in while bending. The four
positions (as seen from looking down on the top of the Square Stop Block) are identified in this
manual by a letter; A, B, C, or D. See Figure 5 on the next page, for the letter and the
corresponding position of the Square Stop Block.
Warning: Always position the Stop Block so that it’s hole is oriented to the right side. Even
though another side of the Stop Block may actually face the work piece. If the hole is
oriented left instead of right, this will result in the Stop Block turning which will cause the
workpiece to move.
Step 2) Set the appropriate Die into place on the Outer Handle/Die Receiver (#9) between the upper
and lower fork. Secure the Die in place by inserting the Short Hitch Pin (#2) through the Outer
Handle/Die Receiver (#9) and the Square Stop Block. The Square Stop Block (#3) is held in
place against the stock as shown in Figure 7 on page 12.
Step 3) Set your workpiece into position. With the Handle (#9) in the starting position, set the Square
Stop Block (#3) as close to the Long Hitch Pin (#1) at the center position, as possible.
Note: To avoid large spaces between the Stop Block, the Center Pin and selected Die, orient the
Square Stop Block differently, or if possible, move it one hole closer to center.
#31980 Page 7

Use of the Right Angle Bend Attachment
You will want to use the Right Angle attachment
instead of the Stop Block when making a right angle
or sharp bend in the stock.
The Right Angle Attachment fits on the Compact Bender only one way.
Step 1) Install the Support Pin (#5) under the Right Angle attachment. This will raise it up so that it sits
above the Ring Assembly/Die Receiver-see Figure 6.
Step 2) Set the Support Pin into the 3rd hole on the Ring Assembly/Die Receiver (#10). Line up the
hole in the top of the Right Angle Bending Attachment (#7) with hole #2 in the Ring
AssemblyDie Receiver (#10)-see Figure 6. Insert the Long Hitch Pin (#1) through
the second hole in the Ring Assembly/Die Receiver(#10) to secure the Right Angle Bending
Attachment (#7) in place.
Note: Your workpiece will not need to be clamped when you are using the Right Angle
Bending Attachment (#7).
Step 3) Mark the stock at the points that you desire to make a bend. Line up the stock so that the
Right Angle Attachment hits directly at the midpoint of your mark.
AB
CD
Figure 5 - Stop Block Orientation
Support Pin (#5)
Figure 6-Right Angle Bending Attachment
#31980 Page 8
Insert Long Hitch Pin (#1)
The Stop and Adjustable Stop Loop
Many times while using the Bender you will need to make repeated bends of the same type and angle. In
these instances, using the Adjustable Stop Loop (#26) or the Stop (#4) will save time and allow for precisely
the same bends.
Adjust the Stop and Adjustable Stop Loop with a piece of scrap metal prior to using your actual workpiece.
This will assure accuracy and aid in obtaining ideal placement of the Stop.

Stop
Step 1) Test and decide the amount and distance of Handle rotation to make the desired
bend.
Step 2) Place the Stop (#4) into the next hole (clockwise) after your rotation is complete.
Adjustable Stop Loop
Use the Adjustable Stop Loop (#26) for stops where a finer adjustment is needed. The Adjustable Stop Loop
allows for more precise stops as it can be adjusted whereas the Stop (#4) is simply placed into a hole on the
Ring.
Step 1) Test and decide the amount and distance of Handle rotation to make the desired
bend.
Step 2) Place the Adjustable Stop Loop (#26) directly at the point where the rotation of the Handle is
to end. Insert Mounting Bolt (#25) through 3/8" Washer (#24) to hold the Adjustable Stop Loop
in place. Tighten on Washer (#24) and Nut (#27).
Step 3) Try a test bend and adjust the Adjustable Stop Loop (#26) as necessary to obtain a precise
bend.
Now that the basic operating instructions have been described; it is time to practice using the Compact Bender.
We are going to show you how to make several useful items such as handles and anchor bolts. We will also
show you how to make letters of the alphabet for use in making decorative signs. Once you practice on the
Compact Bender and learn its capabilities, it should be easy to come up with additional uses for the Compact
Bender based on your interests and work requirements..
Unpacking
UNPACK AND CHECK CONTENTS
When unpacking your Compact Bender check to make sure the following parts are included. If any parts are
missing or broken, please call HARBOR FREIGHT TOOLS at 1-800-444-3353.
Parts List
Part # Description Quantity Part # Description Quantity
1 Long Hitch Pin 2 15 3/8" x 5-1/4" Mounting Bolt 1
2 Short Hitch Pin 1 16 3/8" x 7/8" Mounting Bolt 2
3 Square Stop Block 1 17 1" Die 1
4 Stop 1 18 1-1/4" Die 1
5 Support Pin 1 19 1-1/2" Die 2
6 Ring Assembly Spacer 1 20 1-3/4" Die 1
7 Right Angle Bending Attachment 1 21 2" Die 1
8 Inner Handle 1 22 2-1/2" Die 1
9 Outer Handle/Die Receiver 1 23 3" Die 1
10 Ring Assembly/Die Receiver 1 24 3/8" Washer 2
11 Stand 1 25 3/8" x 1-3/8" Mounting Bolt 1
12 Handle Pin and Hair Clip 1 26 Adjustable Stop Loop 1
13 Mounting Spacer 3 27 3/8" Nut 1
14 3/8" Nut 4
Note: Some parts are listed and shown for illustration purposes only and are not available
individually as replacement parts.
#31980 Page 9

10
PLEASE READ THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM
IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER
NOR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO
THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PROD-
UCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT.
IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY STATES THAT ALL
REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND
LICENSED TECHNICIANS AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK
AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT
OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER
INSTALLATION OF REPLACEMENT PARTS THERETO.
Assembly Diagram “A”
#31980 Page 10

Assembly Diagram “B”
#31980 Page 11
10

MAKING HANDLES
Round Stock
To make handles using round stock, the Square Stop Block (#3) is used rather than the Right Angle
Attachment.
Use a 10" piece of 5/8" round stock and two sections of flat stock for the ends. The measurements given are
general guides only. Measurements should be adjusted according to your preferences and specific needs. If
changing stock size, you will have to experiment to obtain the best points for each bend.
Step 1) Place the Square Stop Block (#3) into place.
Step 2) With the Handle (part #8/9) in the normal position, place the 1" Die on the Center Pin. Place
the 2" Die in the 2nd hole- as in Figure 7. Insert the round stock so that the end extends 2"
down past the 1" Die - see Figure 7. Make the first bend at 90 degrees.
Step 3) Remove the round stock from its original position. Place the second end into the
Bender in the same way as the first bend. You want both ends to be bent in the
same direction. Make the second bend at 90 degrees. Remove from the Bender.
Step 4) Decide on how you want the round stock to fit with the flat stock. Drill 5/8" holes
into the flat stock at the desired position. Insert the round stock into these holes.
Step 5) Weld the flat stock into place from the side where the round stock exits the flat
stock. Smooth away any excess weld material so that the handle sits flush in its place.
Flat Stock
To make handles using flat stock, the Right Angle Bending Attachment (#7) is used rather than the Square
Stop Block (#3). Use a 10" (minimum) length of 3/4" wide x 1" thick hot-rolled flat stock.
Step 1) Set the Right Angle Bending Attachment (#7) into place as previously outlined.
Square Stop Block (#3)
1” Die
Extend 2” past Die
2” Die
Figure 7
#31980 Page 12
5/8” Round Stock
Project Ideas

Step 2) Mark off the material as shown below. Insert the stock into the Bender to the first mark. Bend
to 90 degrees.
Step 3) You may want to set up the Bender with the Adjustable Stop for repeated bends.
Step 4) Flip the stock around and insert the end opposite the bend. Insert it to the 2nd mark and
make a 90 degree bend.
Step 5) Reverse the stock and make the 3rd bend at the 3rd mark. Repeat for the other end and
make a bend at the 4th mark.
Step 6) With a sander or grinder remove any sharp edges or rough spots.
MAKING TUBE CLAMPS
Single Tube Clamp
The following instructions are for a 1" Inner Diameter tube clamp using 4-1/2" long, 3/16” thick x 1" wide flat
stock. See Figure 7 as a reference.
Step 1) Place a 1" die on the center point hole and secure it in place with the Long Hitch Pin (#1).
Step 2) Using the Short Hitch Pin (#2), place a 1-1/2" die in the Outer Handle 2nd hole.
Step 3) Set the Square Stop Block (#3) into the 1st hole on the Ring Assembly (#10).
Orient it as in B (Figure 5 on page 8 of this manual).
Step 4) Insert the flat stock into the Bender so that it extends 1-3/4" beyond the center point.
Secure the stock into position against the Square Stop Block (#3) with a clamp or vise grip.
#31980 Page 13
1-3/4” 1-3/4”1-3/4” 1-3/4”
Square Stop Block (#3)
1” Die
Center Point Hole
2”
1-1/2” Die
Outer Handle (#9)
Figure 9
1st Bend
2nd 3rd 4th
Figure 8

Step 5) Bend the stock past 180°until the die on the Outer Handle slides off of the stock.
Step 6) Remove the Square Stop Block (#3) and the die. Put on the Right Angle Bending
Attachment (#7).
Step 7) With the workpiece as tight against the Long Hitch Pin (#1) in the center as is
possible, make a right angle bend-see Figure 10.
MAKING ANCHOR BOLTS-U BOLTS
Following the directions shown below will allow you to make a 12" Anchor Bolt from a 14-1/4" blank (see Figure
11 above).
As with all bending, you can make shorter or longer Anchor Bolts by changing the size of the blank. Use a
scrap piece to experiment with length and placement of bends.
Step 1) Place a 1" die on the center point hole and secure in place with the Long Hitch Pin (#1).
Step 2) Using the Short Hitch Pin (#2), place a 2" die in the Outer Handle 2nd hole.
Step 3) Using the Long Hitch Pin (#1) set the Square Stop Block (#3) into place. Set
the Stop Block in either position B or D (see section: Using the Square Stop Block). Position
B (3/8" or 1/2" diameter bolts) or D (5/8" diameter) according to the bolt being used.
Step 4) Place the stock into the Bender so that the unthreaded end is extended sufficiently beyond the
Square Stop Block (#3) - 1/2” for 3/8" bolts; 5/8" for 1/2" bolts, and 1/4" for 5/8" bolts).
Step 5) Move the Outer Handle (#9) until you have obtained a 90 degree bend.
Figure 10
#31980 Page 14
Figure 11

#31980 Page 15
Length
Inner
Diameter

MAKING INDIVIDUAL LETTERS OF THE ALPHABET
Directions and tips for creating each letter of the alphabet are
included in the following section. The information given is based on
use of 3/16" flat stock, and a 1" max. width. The letters created by using
these steps are six (6") high and 1" deep.
When creating each letter make certain that you use hot-rolled mild steel. Aluminum can also be used.
The steps are fairly precise, but as with all bending functions you may create you own unique designs and
measurements through trial and error. Use a scrap piece of metal for practice prior to creating the actual
workpiece.
Use a protractor to measure each angle.
To make the following letters use the Right Angle Bend Attachment (#7) for each bend.
Tip: Always double check the measurements on each angle you bend.
Note: Use the Stop or Adjustable Stop for repeated bends at the same angle.
Note: After each letter has been formed, smooth away any sharp edges using a grinder or by
sanding.
The Letter “A”
Two blanks are required for this letter:
• 14" long
• 3-1/2" long
Step 1) Using chalk, mark off six inches (6"). Mark off two inches (2"), and then another six
inches (6").
Step 2) Set the Right Angle Bend Attachment into place.
Step 3) Set the stock in the Bender so that the Right Angle Bend Attachment will bend at the first
chalk mark. Bend to 76°.
Step 4) Make a bend at the second chalk mark. Bend to 76°.
Step 5) Weld the 3-1/2" blank into place about half-way between the legs to finish forming the letter
“A”.
#31980 Page 16
6” 6”2”
1st Bend
2nd

The Letter “B”
Three blanks are required for this letter:
• 8-7/8" long
• 8-7/8" long
• 6" long
Step 1) Using chalk mark off 2-3/4" in from each side. Mark off one inch from the first chalk mark on
each side.
Do the same for the second 8-7/8" blank.
Step 2) Set the Right Angle Bend Attachment into place.
Step 3) Set the stock in the Bender so that the Right Angle Bend Attachment will bend at the first
chalk mark. Bend to 45 degrees.
Step 4) Move the stock to the second chalk mark and bend to 45°.
.
Step 5) Pull the stock out of the bender and insert the stock with the opposite end in the
bender. Make the 3rd bend at 45 degrees.
Step 6) Slide the stock to the fourth position and bend to 45°.
.
Step 7) Weld the completed two 8-7/8" pieces together, these will be the curves in the letter “B”. Weld
on the 6" piece to form the spine of the letter.
The Letter “C”
One blank is required for this letter:
• 14” long
Step 1) Using chalk, mark off 3-3/4" in from each side.
Step 2) From the inside mark, measure in another 1-1/4" and mark it off from each side.
Step 2) Set the Right Angle Bend Attachment into place.
Step 3) Set the stock in the Bender so that the Right Angle Bend Attachment will bend at the first
chalk mark. Bend to 45°.
.
Step 4) Make a bend at your second chalk mark to 45°.
Step 5) Take the stock out of the Bender. Insert the second side. Repeat steps 3 and 4.
#31980 Page 17
1st Bend
2nd
3rd 4th
2-3/4” 2-3/4”
1st Bend2nd
3rd 4th
3-3/4” 3-3/4”
1-1/4”
1”
1”
1-1/4”

The Letter “D”
Two blanks are required for this letter:
• 12-1/2" long
• 6" long
Step 1) Using long blank, mark off 3" in from each side. Then measure in and mark off 1-1/4" on each
side.
Step 2) Make a bend to 45°at the first chalk mark. Slide the stock to the second
mark and bend to 45°.
Step 3) Pull out the stock and insert the opposite end. Repeat step 2.
Step 4) Make certain that both ends of the “D” are equal.
Step 5) Weld on the 6" piece to form the spine of the letter.
The Letter “E”
Two blanks are required for this letter:
• 14-9/16" long
• 2-1/2" long
Step 1) Using the long blank, mark off 4-1/2" in from each side.
Step 2) Make a bend to 90°at the first chalk mark.
Step 3) Take out the stock and insert the other end. Make a bend to 90°at the first chalk mark.
Step 4) Make certain that the top and bottom of the “E” are parallel.
Step 5) Weld on the 2-1/2" piece at the center of the E.
Step 6) Smooth away any sharp edges using a grinder or sanding.
#31980 Page 18
1st Bend
2nd
3rd 4th
1st Bend
2nd
3”
1-1/4”
3”
1-1/4”
4-1/2”4-1/2”

The Letter “F”
Two blanks are required for this letter:
• 10-1/2"”
• 2-1/2"
Step 1) Using the long blank, mark off 4-9/16" in from one side.
Step 2) Make a bend to 90°at the first chalk mark.
Step 3) Weld on the 2-1/2" piece at the center of the F.
The Letter “G”
Two blanks are required for this letter:
• 14" long
• 3" long
Step 1) Using chalk, mark off 3-3/4” in from each side of the long blank. Mark off one inch on each
side as shown above.
Step 2) Set the Right Angle Bend Attachment into place.
Step 3) Set the stock in the Bender so that the Right Angle Bend Attachment will bend at the first
chalk mark. Bend to 45°.
.
Step 4) Make a bend at your second chalk mark to 45°.
Step 5) Take the stock out of the Bender. Insert the second side. Repeat steps 3 and 4.
Step 6) Mark off 1" on the 3" blank.
Step 7) Set the blank into the Bender at the chalk mark. Bend to 90°.
Step 8) Weld the 1" side of the 3" piece to the bottom portion of the “G” . The longer side of the 3"
blank will form the inside part of the G.
The Letter “H”
Three blanks are required for this letter:
•6"
•6"
• 3-3/4"
Step 1) Weld the 3-3/4" blank to the center of each 6" blank. Make certain that both 6"
blanks are even with each other.
#31980 Page 19
3-3/4” 3-3/4”1”
1st Bend2nd
3rd 4th
1st Bend
1”
1st Bend
1”

The Letter “I”
Three blanks are required for this letter:
•5"
•5"
• 5-5/8"
Step 1) Weld the 5-5/8” blank to the center of each 5” blank. Make certain that both 5” blanks are
equally opposite each other.
The Letter “J”
One blank is required for this letter:
• 11"
Step 1) Using chalk, mark off 1-1/4” from one side. From this mark, mark off 3-1/4”. From the second
mark, mark off another 1-1/4”.
Step 2) Set the Right Angle Bend Attachment into place.
Step 3) Set the stock in the Bender so that the Right Angle Bend Attachment will bend at the first
chalk mark. Bend to 45°.
Step 4) Move the blank to the second chalk mark. Bend to 45 degrees
Step 5) Move the blank to the third chalk mark and bend to 20 degrees.
The Letter “K”
Two blanks are required for this letter:
• 7" long
• 6" long
Step 1) On the 7" blank, mark off 3-1/2".
Step 2) Set the Right Angle Bend Attachment into place.
Step 3) Set the stock in the Bender so that the Right Angle Bend Attachment will bend at the first
chalk mark.
Step 4) Make a bend in the 7" piece so that an angle is obvious, but so that it measures
6" when measured tip to tip. Weld the 7" blank to the center of the 6" blank.
The Letter “L”
One blank is required for this letter:
• 10-3/8" long
Step 1) Mark off 4-9/16"” in from one side.
Step 2) Make a bend to 90°at the first chalk mark.
#31980 Page 20
3-1/4”
1-1/4”
1st Bend
2nd
3-1/2” 3-1/2”
1st Bend
4-9/16”
3rd
1-1/4”
1st Bend