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 wigging'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


Just had a radiator built.  The guy welded a bead around 1.5 inch OD
tubing, then spun it on a lathe.  Final product is beautiful.  Works
best with thicker wall tubing.
Lewis.