Tool for bending TIG rod to make a TIG cotter

[stipakb]

Page 243 in the Riggers Apprentice shows using "TIG Cotters" by bending TIG welding rod into a C-type cotter that goes through both stud ends in a turnbuckle.

I bought some 3/32" 316 TIG rod and tried to do it. Making the first bend into a C shape was easy. But making the next two bends, as shown on p. 243, I found I could not do with standard pliers or needle-nose pliers.

I need a better tool to do that. What would work? What makes it harder is that the second and third bends are back towards the turnbuckle so the turnbuckle body is somewhat in the way.

P.S. When I was younger maybe I could have done this with the tools that I have, but now that I have arthritis in my hands and my hands are weaker I definitely need a better tool. Going to 1/16" rod might do the trick too, but I rather use the 3/32" rod if I can bend it as needed with another tool.

Brian Stipak
Portland, OR
S/V Ubiquity, Pacific Seacraft 34

[almanor]

Try a set of duck billed pliers. Kinda like needle nose but with a flat end , gives much more grip and leverage than regular needle nosed pliers I use them all of the time for wire forming.

[John Stone]

Brian
Off Center Harbor has a video of Brion installing the very TIG turnbuckle clips you are asking about. It is very simple.

http://www.offcenterharbor.com/video...nbuckles-pins/

Normally you have to be a member of OCH to gain access to their site but sometimes they dual post selected videos on the web where they can be accessed for free.

John

[stipakb]

Thanks to both of you for your replies.

The video by Brion Toss was very helpful. I now see how to do the inside bend - make it BEFORE doing the other bend. Also, I'll see if I can find a tool with detents in the tip like Brion was using.

Thanks again for your replies.

[Brion Toss]

Hi,
The pliers I use in that video are our Rigger's Pliers. They have detents milled into the jaws that were originally there to make it easier to grab the heads of cotter pins. I later discovered that the work very well to squeeze the legs of cotters together without letting them slip out. And that they allow you to grab the bent corners of TIG rod to finish the bending. I am always reluctant to recommend things we sell here, but they really do work.
Fair leads,
Brion Toss

[Stumble]

I have never seen that trick with TIG wire before, but what a great tip! Now I need to go to the welding shop and the boat. Thanks for making my to do list longer.

[Anton B]

Also, you could bend the first two bends in a vise, and then slip it in and do the rest of them.
Also note that inn the video, Brion is using silicon bronze rod, as opposed to stainless steel. It is likely that the bronze is easier to bend.

Anton

[bplipschitz]

I know I'm late to this party, but I use bicycle spokes. Stainless steel, much harder to work with, but I have a ready free supply of them.