GrayShirt's Mandrel Bend Jig V1

This is a mandrel bend cutting jig I developed as I wasn't thrilled with any of the current options. This jig allows for multiple different tubing sizes and CLRs which saves you a lot of filament. In order to use this system you will need a vertical bandsaw. You must make your own sliding table for the jig to bolt to. I made mine out of a melamine shelf board which you can buy at most home improvement stores. The center hole of the jig must be aligned with your bandsaw's blade for proper cut geometry. I recommend making rails on the underside of the slider to make sure the board slides in line with your bandsaw fence/table for straight cuts. In the future I will make a video about how to properly assemble the system.

The only hardware needed is a half inch bolt, washers, and a wingnut. The threads on the half inch bolt will be a very tight fit on the holes so use a ratchet/drill/driver to spin the bolt through the hole.

Each piece has marks in 22.5 degree increments. These are accurate marks regardless of tubing size/bend radius as long as you use the correct spacers. I like to line up the bandsaw blade with the angle I want using the angle marks on the jig and then lock it in place with the wingnut. You can also use this with 90/45 degree mandrel bends, but it works best if you are buying 180 degree bends. 

The spacers are labeled by full inch or half inch increments. Please note that this is the distance between the legs, not the CLR. To figure out which spacer(s) you need, take your CLR, double it, and subtract your tubing diameter. 

Please note this is a very early version of this design. I have plans for several more features in the future.