Curved taco roll cage gussets

[idickers]

I've used my HF 20-ton press to form the bends. For example, a 1.5" piece of tube would be used as the upper die (male), and a piece of 1.75" tube would be used as the receiving form (female). I've made all sorts of oddly-shaped gussets that wrap around tubes this way.

[Overkill]

Yah, I’m going to give the press idea a try. Thanks everyone.

[BrettW]

Make a hammer form and stretch it. Use steel tube and plate welded together to make the form. Clamp and form into a hammer form. Might not be as clean as a full blown press form, but if you only have to make a couple.

I have always bent tube and welded them into the X and then plated with my dimple died sheet.