Bending Square Tubing with a press?

[donpearsall]

I have a project where I want to bend 2" square 16 gauge mild steel tubing at a 45 degree angle. I know I can buy a $1000 tube bender and dies to do it (or farm it out), but I am on a budget. I have a 20 ton press though. Is there a die I can build or buy to do this? Anyone have ideas? If it gets slightly wrinkled that's OK.
I could also "V" notch and weld, but I would rather bend it if possible.
Thanks
Don

[Bob Drury]

  Don, buy a chunk of 10 ga. cold roll from your nearest sheet metal shop.
  Next draw the inner radius you want and the using tramel points or a compass or a pencil on a string. Trace the outer radius two inches bigger. You can cut them out with a jig saw if that's all you have. Measure the outer radius for length with a 1/4 inch tape measure and cut the outer (heel) piece and using the same method do the inner radius.  Weld em up and grind em down..........  Bob

[John Burk]

Saw the tube in half along the side walls and weld after bending .

[Joe Timney]

I have a die for 1 square...anything larger, I call Art Morrison. They are very reasonable and will do whatever you want...and they are very smooth on the sides in 2 or 2 by3, 2 by 4 or 2 by 6 inch.

[Jorge]

Hey Don, this site might be of interest to you. Its about tube bending and companies that sell equipment for home use. http://www.volksrods.com/forum/showthread.php?t=28830  I hope this site might help you out. Best of luck

[38Chevy454]

I have a die for 1 square...anything larger, I call Art Morrison. They are very reasonable and will do whatever you want...and they are very smooth on the sides in 2 or 2 by3, 2 by 4 or 2 by 6 inch.

Kind of late response, but I second the Art Morrison recommendation.  I used them for the rounded corners of the flatbed on my COE truck.  2x4 tubing mandrel bent the easy way.  Perfect 90 degrees on each bend, and maintained the nice rounded corners on the rectangular tubing.  I actually had two big U bends made, one for each end of the flatbed.  I believe they sell stock bends with around 24 inch leg lengths.