What size rod/wire do you think this is formed from? You can buy 4mm fencing wire (note galvanised you'ld need to clean at welds). that would bend around timber formers

I'm guessing that a heavy duty enough steel frame from rolled up sections and you could cold form the stays around that just using long lengths and clamping at the intersections – say 4-5mm hot roll. Just need to make the bending rolls first and then the pattern.

There's a good chance the original is made from tube – or it could get heavy. I know my OH would take one look and shake her head at a dust trap like that..

(or make it out of wicker and spray with hammerite)

In solid steel ,that would be a fair weight . It could easily be done in plastic, using a hot air gun for the welds.then spray it with a can

You don't actually want a metal bender as per first link for these curves as they do sharp angles. you want bending rolls – like a formit . or make something incredibly simple from a bit of turned bar ends but we won't tell if it turns out you need the full machine.

BTW it would look a lot better if you avoid the equatorial joint and load the bulb from above.

Edited By Bazyle on 06/02/2016 09:46:03

Seems to me that the globe is made up of about 16 lengths of wire all the same shape, distributed around the sphere. Would it be possible to make a jig for one piece (probably take a bit of faffing to get the shape right), then just make as many as you need. Also probably need a jig to hold them in place for welding, but if you are going to turn the top and bottom finials, it shouldn't be hard to drill them to support the wire in the correct place using a divider in the lathe. Bending 4 or 5 mm wire by hand is not so hard. Agree with Bazyle – attach it to the fitting at the top so it can be dropped to fit the bulb – much better than the ugly equatorial break.

To get that appearance looks difficult to me. They are not lines of longitude, slewed around to get the angular effect. They are bent side ways(along the line of latitude )as well. i would try and find a drum, then free hand draw the "sideways" bend shape on it. Once the "sideways" off set has been determined, make a jig up from jigsaw cut chip board and laminated, so you are make a short section of half the drum. Side guides are now required, router cut groove? Big nails pushed into predrilled holes? Wooden blocks screwed on? I would bend the semicircles with a couple of inches of extra flat bits at the ends . So at the top and bottom have a big washer with a huge hole in it, so the flats can be clamped to them , then spot welded then the excess cut off. Hope SWMBO appreciates the work involved.

Frank

Seeing the required end product, my thought was Bending Rolls.

If you want another project, why not make some? The G H Thomas book (Model Engineering Techniques – from memory) has text and drawings in Chapter 18 for a 10 "wide set. I've just finished making a 12" set based on this geared design. If SWMBO complains about the leadtime for her lights, explain that you are making the tools to do the job. Hopefully, she will realise that it is not a "can you just" job.

Howard

The larger Formit has grooves in the rolls for wire forming. Don't know about the smaller. Remember the ends remain straight for an inch or so in this type of former. It is better to use the longest wire possible and cut up after forming. Practice with coat hangers though wire ones are becoming collector's items so might need to be kept for their true purpose in life – replacement car aerials.