I used the Earl's Performance Plumbing
1 1/2 inch OD tube beader on these two small tubes
today. I had to make a mandrel that fit
the inside of the tube so I could hold it from turning in
a 3 jaw lathe chuck during the beading process.

The large wrench is needed for the 2 inch
version and the smaller wrench is needed for the
1 1/2 inch version.

Perhaps a better way is to clamp the Earl's beader in a
bench vise and use a strap wrench to rotate the tube.

It is a rather time consuming process. The balls
must be moved out over and over again as the tube or
the beader is rotated over and over again.

.065" wall 6061 T6 is at the limit of what these
things can do. 6061-O is probably a lot easier.
Thinner walls would also be easier but they are
harder to weld.

The balls are staked in so a bit of filing around
the balls is needed to get rid of the manufacturing
burrs that tend to gouge the inside of the tube.

Also the beader tends to distort the tube slightly and
lock itself in so both ends of the tube must be open to
knock the beader out with a large socket and hammer
when done.

Paul Lamar

Thanks for the review Paul. Very helpful.
C. Smith

I woke up this morning with a better idea. Shear some
.049" thick 6061 T6 sheet .125" wide.
Bend it around the tube and tack tig weld or braze it on :)

Paul Lamar

After following this for a while and seeing the last post I'll share
what I did.
I took the next size up tube that was a slip fit on the tube needing
beading and turned a handful of small collars / beads. I slipped one
of these over the tube and welded it in place with low temp aluminum
welding rod.  This stuff is a little tricky to use but all you need
is a propane torch.  The beads aren't as pretty but they won't come
off and are simple to do.
Randy Lewis

So Paul, I'm curious as to why aren't you using your "Wiggins" couplings
on this demo engine?  They are easy to weld and are very robust.
 They also make it easy to disassemble and reassemble the coolant system.
I've been using them for years and often point them out to others as
a superior alternative to using hose clamps. Mark S.

This is not the demo engine. This is a turbo firewall forward
package I am completing. I sold it along with my Kis Cruiser kit.
I needed some very sharp 90 degree bends so the Wiggins's would not fit
due to a very low Kis cowl top relative to the thrust line.
There are a couple of places they will fit and I'll check
with the owner and see if he wants to spend the money.

Paul Lamar




If you are going to weld; Just weld some bead in six places around the tube.
Another way is to bend some small Al Tig rod around the tube and then Tig it
to the tube. It does not need to be welded all around as spot welds will hold
it in place enough to keep the hose in place. The seal is where the hose is
clamped.

Dale Davies