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Old 12-07-2012, 10:04 PM   #1
Vesku
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Default DIY convoluted copper

I've been destroying a lot of copper tube, but finally got my tool working:



Gutted:



CFC:



Double copper test (ugly):



Test plot, 3.5L/min flow for hot water, 10L/min for the cool (12C):



I used 15mm copper for the copper/pvc-CFC and some imperial about the same size for the double copper CFC.

The tool is just a hole in 2X4 and adjustable bearing. Annealed copper works better, but "hard" copper can be used too. It needs re-annealing after the grooves are made to be able to make the coil.

For the next one (a shorter one for my CFC-HERMS), I'll try to "twist" the outer copper as well (except the bends). And it will have a shape of something like this:

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Old 12-07-2012, 10:11 PM   #2
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Looks awesome.

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Old 12-07-2012, 10:19 PM   #3
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I would love to see some pics of the jig you used on that. It looks great!

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Old 12-07-2012, 10:30 PM   #4
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Quote:
Originally Posted by thelorax121 View Post
I would love to see some pics of the jig you used on that. It looks great!
I second that!

Looks great!
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Old 12-07-2012, 10:34 PM   #5
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I made this for the double copper:



Here's some of the "twisting tools":

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Old 12-08-2012, 12:57 AM   #6
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Looks awesome!

Now, please forgive some ignorant questions. I can't really see the twisting tools very well. It sounds like you made grooves in the tube and then twisted? Can you go into more detail on the process? Thanks!

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Old 12-08-2012, 04:05 AM   #7
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I want to you guys to think too Everything is made so easy nowadays with the google and all

It's basically a thread die, a very dull one. Drill a hole that has two angles. One angle is for the angle that the bearing is against the copper and other for how fast it moves when you roll it on the tube. I'll took a video clip next time I'm doing something (may take some time as I'm totally out of money. I've to wait until the scrapyard has some copper...)

I don't know how the real tools work, but I would guess the process is the same. I don't think that the tube is actually twisted at all, just "grooved".

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Old 12-08-2012, 04:25 AM   #8
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Thanks, that clears up alot.

I'm not very tool savy and wouldn't have known to look up thread die, but when I first saw it I thought it looked a bit like it was gone over with a dull pipe cutter on a diagonal somehow.

It's really clever and a very professional looking result.

I'm sure everyone would appreciate a video demonstration.

Nice work!

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Old 12-08-2012, 06:00 AM   #9
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+1 one to JsGuitar.

Your craftmanship and ingenuity are amazing. Looking forward to more!

Dan

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Old 12-11-2012, 06:51 AM   #10
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I`ve just notice this thread and was interested in having a go at producing a homemade convoluted tube, just wondered if anyone else has been sucessful in copying the idea.

More experiments to follow

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