Rolling a 5″ gauge copper boiler barrel

[Peter Simpson 3Participant @petersimpson3]

Looking to roll a 5" gauge copper boiler !/8" thick copper plate. What rollers would be suitable ? There load of rollers on the Bay. but they only go up to 1.2 mm thickness

[Peter Simpson 3Participant @petersimpson3]

[Andrew TinsleyParticipant @andrewtinsley63637]

You don't need rolls. I simply make a former and bend the sheet around it. You will need to keep annealing the sheet between bends as it will work harden. Fully annealed copper is surprisingly soft and bendable.

Andrew.

[noel shelleyParticipant @noelshelley55608]

BIG ish ones ! Soft hammer and a round wooden block, anneal as needed ! Easy way would be to pop round to a friendly small engineering works and offer beer tokens, may be a lunchtime job ? Or copper tube at 3mm wall ? Good luck. Noel

[Nick Clarke 3Participant @nickclarke3]

Has your local ME society got some larger bending rolls? – mine has. Where are you approximately in the country?

[Dave HalfordParticipant @davehalford22513]

Blackgates do 5" copper tube in 10G.

[duncan webster 1Participant @duncanwebster1]

LBSC recommended bending boiler shell round a downspout. I don't! I'd take up Noel's suggestion, one anneal will get you from flat to round at 5" diameter. However, if you're aiming for the usual 80-100 psi working, you can get away with 13g for a round shell, more difficult if the back end is opened out for the firebox outer wrapper. If you go down this route take your boiler inspector along with you

[Speedy Builder5Participant @speedybuilder5]

If you are looking for rollers, make sure the are "slip rollers" so you can slip your tube off the end once rolled !

[Paul LousickParticipant @paullousick59116]

Copper sheet is expensive, especially if you stuff it up and have to buy a second sheet. A set of slip rolls is also expensive and a costly ornament if you do not have another use for them.

For a one-off project, best to take the plate to a local engineering business.

[Peter Simpson 3Participant @petersimpson3]

After phoning numerous engineering companies, non of which were remotely interested in doing the work. I have two choices.

Buy flat 3mm sheet and form it round a 4" tube.

Buy 5" diameter 10 SWG tube a cut the relevant triangle out to form the the 4.5" diameter smoke box end.

Sheet is cheaper but tube may be easier.. What the thoughts of the experts ?

[Speedy Builder5Participant @speedybuilder5]

I am surprised that (Unless Peter has has a personal message) nobody here has offered to roll Peter's barrel.

Bob

[JasonBModerator @jasonb]

Maybe not many members with large enough rolls, and from his latest post looks like it would really want rolls that can do tapers

[Simon CollierParticipant @simoncollier74340]

I’ve rolled 3 mm copper using large rolls donated to the club. I had to keep annealing it with my 2944 burner. Rolled to 6-1/4” with slight taper. The member who donated them moved away and some time later they vanished. He undonated them! Hardly anyone is going to have rolls big enough. I suggest making a former from stacked plywood disks. With multiple annealings and using hands, hammers and band clamps, it can be done. Buying 5” tube would be so much easier.

[duncan webster 1Participant @duncanwebster1]

If OP reveals where he is based we might be able to suggest firms we know of

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