Baileigh Industrial News

Charlotte, NC – Baileigh Industrial sponsored driver David Reutimann took advantage of a race ending red flag to claim the first NASCAR Sprint Cup series victory of his career at the Coca-Cola 600 held on Memorial Day.

Reutimann pilots the #00 Toyota Camry for Michael Waltrip Racing (MWR), with whom Baileigh Industrial entered into a multi-year sponsorship contract in 2008. In mid 2008 MWR brought their chassis fabrication in house using Baileigh Industrial metal fabrication equipment in the construction of their Nationwide and Sprint Cup cars at their Cornelius, NC location.

Baileigh Industrial is a manufacturer of world class metal working equipment with facilities in the United States and England.

Handrails by Wayne Keller of Keller Sheet Metal in Clinton, MD. Wayne used his RDB-125 and AF-360 to make these handrails out of schedule 40 pipe.

Looks great, Thanks Wayne!

Las Vegas, Nevada

Baileigh Industrial was honored to have hot rod legend Chip Foose stop by at our booth at the recent Fabtech show held in Las Vegas. Chip took some time out to look over some of our fabrication equipment, especially our MH-19 Power Hammer. As you can see in the pictures, he even got a little “seat time” in on his own.

Thanks for stopping by Chip!

April 3, 2009

Baileigh Industrial sponsored driver David Reutimann delivered his best qualifying performance of the year at Texas Speedway putting his #00 Aarons Toyota Camry on the pole for the start of the Samsung 500.

David drives for Michael Waltrip Racing (MWR), with whom Baileigh Industrial entered into a multi-year sponsorship contract in 2008.  MWR has since brought their chassis fabrication in house using Baileigh Industrial metal fabrication equipment at their Cornelius, NC facility.

Congratulations David on your pole and 11th place finish!

Craig at Hot Ride bends these types of custom roll cages and accessories with his RDB-100 manual tube bender and Bend-Tech-SE layout software. Thanks Craig!

Just wanted to say thanks for my new shrinker stretcher from Baileigh Industrial. It was a very difficult decision picking a tool from such a great selection. As you might have seen in some of the pictures in my posts, I already use their shrinker stretcher. and the bottom line is it works. I wanted to pick something that I would use a lot, and so far I’ve used this tool on every panel I’ve made for Johns 27 T. The reason why I chose another one is because now I can leave the shrinking jaws in one and the stretching jaws in the other. I have used many different kinds of these tools and this one is definitely the best bang for the buck. It does 18 gauge steel no problem and that’s what I need since that is what i am most commonly using. most of them out there can stretch but any one under 1200 bucks that i have used cant shrink 18 gauge worth squat. Take it from me I’m about as hard as they come on tools and this one works like the day I got it. Thanks Baileigh, I’m sure I will be using it every day.

Sincerely
~CustomJ

View more at Jalopy Journal

Here at Baileigh, we sure do get allot of calls from guys wanting to bend handrail. Whether they are just starting out, or want to bring their bending process “in house”. Baileigh has several benders that work great for all sorts of handrail applications; a guy needs to ask himself what “bells and whistles” he would like on his bender and how much physical labor he wants to do.

Manual benders

These are great for small jobs and small budgets. The RDB-100 works off of compound leverage (kind of like an old 1970’s car jack) with every swing of the handle gives you around 7 degrees of bend. Although this bender is easy to use, if you have a ton of bending, you might want to consider a hydraulic bender.

Hydraulic benders

The RDB-125 is a perfect fit for anyone on a budget looking to get into bending handrail. It can bend around 50 degrees in 10 seconds or so, but then the ram must re-stroke before bending the next 50 degrees. A great bender for smaller shops and light production runs. If you are looking for faster bending speeds without having to stop every 50 degrees, you might want to take a look at our one shot benders like the RDB-150AS or the RDB-175.

The RDB-150AS  is the original rotary draw bender from Baileigh. It has been around for years and there are thousands of them out there. Drop on tooling for fast tooling changes, and a quick release counter bend die system for fast loading and unloading of the material. The RDB-150AS has a hand controlled forward and reverse knob and a single bend angle control or Auto Stop. It will bend 180 degrees in one shot in about 30 seconds. Here is a video:

Our RDB-175 is the result of years and years of customer feedback on the RDB-150AS. We took the 150AS design and improved on everything. It is foot operated for hands free operation; all of the hydraulic components are tucked away nicely in the cabinet. A fast ratcheting counter bend die positioning system and a one shot, 180 bend speed of 13 seconds.

Programmable benders

RDB-250 benders have high bending speeds and are extremely accurate. With the ability to store 170 jobs with 10 bends per job, these benders are top of the line solutions for handrail applications and can bend 180 degrees in 9 seconds. Positioning tables are also available for these benders for extremely accurate positioning of tricky applications. Here is a video:

RDB-300 has the same features as the RDB-250, but has larger center line radius capacity (up to 15”!). Here is a video:

Our model RDB-350 carries a whopping 24” CLR capacity as well as the ability to bend up to 2 ½” Sch. 40 mild steel pipe. This is the ultimate job shop bender! Video:

Tube Notchers

A good tube and pipe notcher will come in handy when doing handrail and save the operator hours of work and hundreds in consumables.

Hole saw notchers are probably the most common notchers out there because they are inexpensive and you can get upwards of 100 notches from 1 holesaw when done right. We offer an entry level TN-200H that can be operated in a drill press or with a 1/2″ drill. Unfortunately if you have a ton of notches to make, you will grow tired of it in a hurry.

The TN-300 is our high end hole saw notcher. Hands down the best holesaw notcher on the planet. Easy to load and easy to use. It boasts a 1/2 horsepower motor with direct drive into an industrial grade oil filled gearbox. The heavy duty cutting head is fed into the material with a large feed wheel. What makes this notching machine unique is that the head of the machine moves on a track of precision V-Bearings, which combined with the large hand wheel makes notching any material a breeze. Here is a video:

Accessories

Bend Tech Pro software is also very popular with the guys who are just getting started. It makes tube bending simple by allowing you to design your projects right on your computer screen. After designing your project, just click a button, and it will print out a build sheet for each tube. Showing you how long to cut your tube, where to start and stop your bends. It also will print out a notching wrapper as well. These make notching the ends of your tube simple and accurate. Just cut the wrapper out with a pair of scissors, wrap it around the end of your tube, trace it with a sharpie marker and notch your tube. When you are done, you will have a bunch of tube lying on the ground that will be bent and notched that will fit together perfectly.

AF-360 is a simple angle level. It allows you to track your rotation of your pipe when bending. Multiple bends can be made in the same plane easily with the AF-360.

If you are thinking of starting up a business or would like to get into bending and installing handrail, give us a call. We are familiar with, and have seen just about every handrail application out there.

Over the course of the day we get quite a few inquiries from the off road and ATV crowd. Off Roading and Baileigh Industrial fabrication equipment go hand in hand. Most guys are looking to bend a roll cage for their Jeep or truck similar to the following:

One aspect of off-roading that has taken off in the past few years is rock crawling. These vehicles are fabricated for one purpose – to get over the nastiest terrain imaginable! In this sport having the best equipment on the market is essential to building a rig that can withstand the punishment on a day in and day out basis, and Baileigh Industrial saws, benders and design software are crucial to achieving that goal.

But do not go away thinking that our equipment is only for the “experts” in the crowd. Many items on a typical 4X4 or ATV can be produces with a little time and the right equipment.

Exo Cage

Shock Hoops

Brush Guard or Stinger

ATV Accessories

All of the above projects can be made fairly easily in ones garage with a little imagination, a tube bender, a tube notcher, a saw, and an angle level.

For most applications a rotary draw tube bender is necessary to produce the somewhat “tight” bends needed for most projects. These machines come in many forms from manual, to hydraulic, to fully programmable. Baileigh tube benders all utilize the same tooling throughout the lineup enabling the user to achieve the same high quality bends regardless of model purchased. One very popular model in the Baileigh lineup is the model RDB-125 rotary draw bender. This unit is economically priced for the garage mechanic yet has the power and precision that professionals demand. Die sets are available for most any size OD and center line radius. The most popular off road die sets are 1 1/2″ and 1 3/4″ and usually with a 5 1/2″ and 6 1/2″ center line radius. Most customers will also purchase a 1″ die with a 3″ CLR for luggage racks and grab handles.

Achieving a precision cope is one of the most important aspects of a high quality build. Fitment is crucial in these areas and Baileigh notchers are designed to deliver time and again with a full line of pipe and tubing coping machines at various price points to accommodate any size budget. Hole saw style, end mill type and abrasive notchers are the most popular.

An accurate saw is a must for any shop. Some of the most popular types among the off road fabricators include band saws and abrasive saws or “chop” saws. One type of saw many times overlooked is the cold saw. Each type of saw has specific strong points and weak points. Baileigh Industrial carries a wide assortment of these models to suit any job you may run into and all at a price you can afford!

Bend Tech Pro software is also very popular with the guys who are just getting started. It makes tube bending simple by allowing you to design your roll cage, rock crawler, racecar or chopper frame right on your computer screen. After designing your project, just click a button, and it will print out a build sheet for each tube. Showing you how long to cut your tube, where to start and stop your bends. It also will print out a notching wrapper as well. These make notching the ends of your tube simple and accurate. Just cut the wrapper out with a pair of scissors, wrap it around the end of your tube, trace it with a sharpie marker and notch your tube. When you are done, you will have a bunch of tube laying on the ground that will be bent and notched that will fit together perfectly.

We have seen some pretty impressive designs from some of our customers, and we know there is much, much more to come!

Working here at Baileigh, we get to talk to people from many different industries, and get to see many different rolling applications. From Engineers and their Industrial applications like building bridges and giant structural steel to small weld shops doing ornamental projects and spiral staircases we see it all. My personal favorites are ornamental and architectural applications.

These machines have several different names depending on where you are from and who you are talking to. Some common references include roll benders, angle rolls, ring rollers, pyramid benders, section benders, tube and pipe rollers, and profile benders. The list can go on and on.

All of Baileigh’s roll benders come equipped with our “standard” roll sets. This tooling consists of a series of large hardened spacers in several different sizes and thicknesses. This allows the user to configure the tooling to fit any material with a square edge. This standard tooling allows you to roll square, rectangle, flat bar, angle, C channel, I beam, some solids, and some extrusions. Tube and pipe rolling requires special roll sets for each individual size.

Roll bend tooling is available in hardened steel (smooth and knurled) or nylon. Nylon roll sets help to minimize any scratching or tooling marks on the rolled material. They are popular with stainless or anodized aluminum section and angle bending applications.

Here are some common questions we field on a daily basis.

How does a roll bender work?

A roll bender works by introducing pressure and creating “pinch” as material is being driven or rolled through the roll sets. This force is applied to the material by changing the distance between roll center lines with either the top roll (single pinch) or bottom rolls (dual pinch).

Is section and bending hard to learn?

Absolutely not! Angle bending is a simple process that can be learned by even a novice in a couple of hours.

How many rolls are driven?

Our manually adjusted (top roll) benders have 2 driven rolls on the bottom. Hydraulically adjusted roll bender utilize 3 driven rolls. Keep in mind that the more difficult the material is to bend, the more “traction” is needed to move the material through the tooling. This is one of the major advantages to a hydraulically adjusted roll former.

How do I repeat parts on a roll bender?

It depends on what type of machine you have. Our hydraulic machines feature a digital readout with a memory. This memory setting allow the operator to set a single stop point for the adjusted roll. When the desired radius is achieved, just push a button and it will save that location. This number indicates how many inches (or millimeters) of pinch you are creating. The greater the pinch, the tighter the radius of your finished material.

There are several ways to repeat parts on a manually adjusted roll bender. You can make a template of some sort and roll your material to match the template. Also standard is a scale attached to the top roll that shows how many millimeters of force have been applied to the rolled material. When you reach your desired radius, remember that number and roll to that same spot next time.

What is the difference between a single pinch angle bender and double pinch angle bending machine?

A single pinch machine applies its force through the adjustment of the top roll in relation to the fixed lower rolls. A double pinch machine’s top roll is fixed, and pinch is crated by forcing the bottom rolls up around it. A double pinch machine has the ability to reduce the amount of “flat” material left after the roll bending process is completed as the material can be pre-bent much the same as a plate roll or slip roll.

How do you coil material?

Coiling is a simple process whereby the lateral guide rolls are adjusted away from the machine, causing the material to push away from the framework of the machine as it operates. Doing so causes the finished material to loop around and “coil”.

Can I use this angle bender both vertically and horizontally?

All of our roll benders can operate in either the vertical or horizontal position. This adjustability allows you to lay the bender on its back (horizontal) for large radius work where overhead space and operator efficiency come into play. Baileigh pyramid benders require no changeover to operate in either mode.

While I hope this has been informative for you, the information here is only the tip of the iceberg when it comes to section bending and roll forming machinery. The possibilities when profile bending is as limitless as the imagination. Should you have any further questions or comments regarding the information contained within this blog, or just want to receive some more information on Baileigh Industrial angle bending machines, feel free to give our qualified sales team a call. We would love to hear from you and help get your ideas off the ground!

MANUAL, SEMI-AUTOMATIC, AND AUTOMATIC

One of the most frequently asked questions here at Baileigh Industrial is “What are the differences between manual, semi automatic and automatic cold saws and band saws?” This may seem self explanatory, but even the most grizzled metalworking veteran has pondered this topic on more than one occasion.

Manual Saws

This category of saw takes its name from the fact that the operator needs to perform many of the functions of the saw process “manually”. No, not using a hacksaw. Rather, the operator must manually advance the material between cuts, clamp the material in the vise, and turn on the blade. On a horizontal bandsaw the laborer can choose between using the pull handle with trigger mechanism to perform the cut, or can set the hydraulic descent cylinder to the desired feed rate and let gravity take its course. A manual coldsaw will have only a handle and trigger mechanism with spring assisted return.

This class of saws is very popular in shops where a variety of cut lengths and angles are performed by a number of different users. More of a “job shop” atmosphere as opposed to a production type facility. Manual metalworking saws come in a wide variety of sizes ranging from fully portable all the way to 13”+ round capacity.

Semi-Automatic Cold Saws and Band Saws

What sets the semi-auto metal cutting saws apart from the manual models is the decrease in the amount of manual labor involved in the cutting process. Where every aspect needs to be attended to with a manual saw, the semi-auto saw, once set to the desired feed rate, blade speed and initial vise opening, requires only the placement of your material at the cut point. Once this is achieved, the operator simply depresses the foot pedal and the saw does the rest – vise clamps, blade and coolant turn on, saw head comes down and performs the cut. At the point that the saw is finished with the desired cut, the blade and coolant are shut off and the head returns to the open position. Once the head reaches the top, the vise is released and the material is ready to be advanced for the next cut.

In addition to the reduced labor intensity of the semi-automatic saw are the added benefits of increased blade life and a more accurate cut. This is achieved through the elimination of the “human factor.” By this I am referring to the tendency of the operator to pull down on the handle with too much pressure leading to excessive heat buildup and abnormal blade distortion. These two issues are the biggest enemies to accurate and productive cold saw and band saw usage.

Automatic Saws

Taking the production level up a notch are the fully automatic metalworking saws. Generally used for high production runs, these saws are capable of running all day with little to no supervision. All aspects of the metal cutting process are preset prior to cutting to ensure the highest accuracy and efficiency.

An automatic saw takes all of the features of the semi-auto models and ups the ante with automated material feed systems. Saws can be programmed for multiple cut lengths and many have the ability to sort out the finished pieces. Many of the saws in this class have bundling capability and rack feed systems to allow minimal downtime and more profit. Maintenance is reduced through automated oil systems and chip removal augers.

For those applications where labor is at a premium and there is a need for a large capacity, high production saw an automatic metal cutting band saw or cold saw is the right choice.

I hope this has cleared up some of the questions regarding the differences in basic saw types without getting too in-depth. While there are a lot of saws on the market, knowing the basics will help make your choice a lot easier. At Baileigh Industrial we know that every purchase you make is important, and it is our sincere wish to help you achieve –

Precision, Performance, and Perfection
Jon Newberg
Sales Manager
Baileigh Industrial Inc.