Mast steps fabrication.

Inspired by Video https://www.youtube.com/watch?v=S_hD4dJGUgM, I decided to make steps in my house.

 

As stock I used 6063-T52  0.1875x1.25x12" aluminum bar. I found it on Xometry cite for https://supplies.xometry.com/6063-aluminum-bar-rectangleom-18084-12-0.html $1.44  per piece.

Originally, I planned to bend bar in vise but when i did the bend i figured there too much stress on 90 degree bend if you do it over sharp corner, vise jaws marks hard to do middle bands as well, due to vise screw appears on the stock way. 

So, i would need to have bender to do radius bend.

Buying  bender for one-time-use I decided too much. I built one from pieces of metal i had in my garage.

Pats used:

Steel angle 1.5" - ~10" length

Steel bar 1.5x0.25x16" - two bars for turn lever

3 x 1/2" bolts with nuts and washers.

4 ball bearings ID 1/2

Drilled holes , cut a little with angle grinder, than screw all together.

 

Screw to the workbench.

Bender in work.

 

 

Distance between axle and bearings is minimal. Actually I filed holes for bearings axle to male stock to be inserted in between.

Here you can see 3 holes drilled in the bench. I used them to make identical bend distances. I inserted pin (center punch) in them to stop stock on exact positions. 

 

Vertical post is gauge to make right bend angle.
 

Final product - 26 identical steps. Tool building 30 min, All parts was bent in 20 minutes.