Re-think on wire bender for making chain links

[thehomeengineer]

Hi All

After posting the wire bender to make the chain links using a M8 nut and bolt, Wire bender for making small chain links for model traction engine steering chains I wasn't totally happy with the shape of the links and how fiddley they were to produce. So this was playing on my mind , I had to think of a better way to form the links, and I couldn't find anything on the net on how to form small chain links . So after a few days contemplating the best way forward I put pen to paper (yes a PEN with real ink) and started to play around with some ideas on how to improve the shape and production of these tiny links.

As I need to make approximately 120 links for the steering chains on my 1" scale traction engine I also wanted to be able to cut the wire to a constant length so also designed and built a wire cutting guillotine (I will post on HMT in another post)

Below are the photos and results of the new wire bender:


Photo of the completed tool and the first few links bent on it.


The bender forms the wire link in two stages around the pin located on the centre line of shaft. The length of wire was calculated to be 13.8mm and a datum mark was set on the shaft with a small chisel mark at approximately 7mm from the centre of fully formed link so the joint would be in the middle of link. (mark highlighted on photo).



First links fitted to each other


new link shape is a lot more pleasing on the eye (in my opinion)



Old former also didn't close the link fully.
Old link shape using nut and bolt wire bender has square ends due to the way the former was made.

As the wire is only 1mm 0.040" diameter and copper it is easy to bend.To aid the movement I didn't feel it was necessary for a handle so I simply knurled the out diameter to give grip when rotating. The Bender guide also acts as location and stops the outer from sliding all the way down the central shaft.

I am very happy with the shape and have gone into full production

thank you for viewing
The Home Engineer

[bobs409]

Wow, what a difference! Nice job.

[kess]

Much better result.

[thehomeengineer]

Hi All

I have put a video together, to show the process of making the chain links. This video shows both the wire bender and the wire guillotine.

Many thanks
The Home Engineer

[kess]

Amazing both of them.

[thehomeengineer]

first few links soldered together

[olderdan]

Firstly good on you for making your own chain instead of using ready made model chain, I was initially surprised at your use of copper but we know by now you know what you are doing. Do you plan to nickel plate or paint black?.

[thehomeengineer]

Hi olderdan
Thank you for the kind words
I did think about steel links and silver soldering. However I would have had to buy the steel and had the issue of high temperature soldering small links and then having to clean etc. The copper links are surprisingly strong as the links are very small and the tight radius helps to stiffen up the links. Another advantage is the fact I can soft solder each link with little, or should I say less chance of effecting the previous joints by controlling heat from an iron and is very clean. I my shot blast the chain and use etching primer so it has a good key and then paint. The model is also very small 1” scale and my intention is to have it mounted in a cabinet for show. The engine could be steamed but to be honest it is all about the build for me rather than steaming. It will run on compressed air when friends family etc show some interest but I expect it to stay on the shelf and I will always have a sneaky look as I walk pass, as you do when you have made something you are happy with and understand all the effort and time you have invested.

All the best
The Home Engineer

[DIYer]

Thanks thehomeengineer! We've added your Small Wire Bender to our Metalworking category,
as well as to your builder page: thehomeengineer's Homemade Tools. Your receipt:

Small Wire Bender by thehomeengineer

tags: bender, chain

[thehomeengineer]

Both chains made ready for light shot blast, etched primer and paint. The chains are 220 mm (9") long and each joint soft soldered.