aluminum rod inside styrene tube

[peteski]

As far as solder being "saggy", if using solid core solder (no flux) and at a diameter large enough for 1:24 exhaust headers, the solder wire will be more than stiff enough to hold its shape, especially the more recent lead-free plumber's solder.

[BK9300]

1 hour ago, SpeedAndViolence said:

Do you have personal experience with this?  I've tried Googling 'hobby tubing bender' and numerous other terms, but I'm not finding much. 

I do not have any experience with this tool, but I have one ordered and think it will work quite well.  It's advertised as being able to bend quite small diameter rods/wire.  I also want to try it out on small diameter, aluminum tubing and styrene tubing, with smaller brass support rod inside the tube, to see how/if the bending turns out.  It will still be useful for wire and brass rod, I'm hoping.

[NOBLNG]

1 hour ago, SpeedAndViolence said:

Do you have personal experience with this?  I've tried Googling 'hobby tubing bender' and numerous other terms, but I'm not finding much. 

 

7 minutes ago, BK9300 said:

I do not have any experience with this tool, but I have one ordered and think it will work quite well.  It's advertised as being able to bend quite small diameter rods/wire.  I also want to try it out on small diameter, aluminum tubing and styrene tubing, with smaller brass support rod inside the tube, to see how/if the bending turns out.  It will still be useful for wire and brass rod, I'm hoping.

Here’s a video of it.

https://www.youtube.com/watch?v=UHYbNhLImJg

[SpeedAndViolence]

My main goal is to be able to bend styrene rod to make roll cages, and solder for exhaust tubes. 

[peteski]

You did say "rod". Unlike metal (aluminum copper or tin) rods , polystyrene rod when bent will not retain the formed shape. It will try to flex back to its original shape. A "rod" by definition is solid material(not a hollow tube).

But a polystyrene tube with a metal rod inserted in it would retain its formed shape much better.

[Straightliner59]

10 hours ago, SpeedAndViolence said:

My main goal is to be able to bend styrene rod to make roll cages, and solder for exhaust tubes. 

Plastruct's ABS, or the stuff in the Ebay link I posted above work great for roll cages, etc. (they're the same material). Just work it slowly to shape with your fingers--their warmth will help with the process. For headers, I would recommend aluminum armature wire. It comes in several gauges, it bends easily, and it's much lighter than solder. I posted the interior of my Super Gas Vega, above. I built that cage using the ABS. I drill and pin the joints. I built the headers for this Porsche from armature wire. I don't recall the gauge, but it's .062". It's uniformly sized, as to diameter, and round, as well. Hope this helps.