How to Safely Bend Conduit Without a Bender

Bending conduit without the proper tools can be challenging, but with some creativity and elbow grease, it can be done safely. Here's how to bend conduit without a bender:

Gather the Right Materials

First, you'll need conduit, obviously - the most common sizes are 1/2" and 3/4". Make sure to use EMT (electrical metallic tubing) or rigid conduit. Do not use flexible conduit for this technique as it will likely kink. You'll also need:

• A heat source - such as a propane torch or heat gun to soften the conduit
• Rags - for holding the heated conduit sections
• Gloves - for protecting your hands from the heat
• A sturdy vice - for securing the conduit while bending
• A pipe wrench or large adjustable wrench - for twisting the conduit
• Eye protection - safety glasses for protecting your eyes
• Sandpaper or emery cloth (optional) - for smoothing rough edges

Prepare the Conduit

Before heating, determine the bend measurements and mark the conduit with a marker at the points where you want the bend to start and end. Make sure you leave several extra inches on each end to secure the conduit in the vise.

Also, sand and wipe down the sections to be bent to remove any dirt or oil so the conduit accepts the heat more evenly.

Apply Heat

Next, use your torch or heat gun to apply heat along the bend area, moving the flame back and forth slowly and evenly. Concentrate on the inside radius of the bend, where the conduit will compress as you bend it.

Heat a 2-3 inch section at a time until the conduit softens and you can see the sheen of the metal change color slightly. Be patient and avoid overheating any one spot to prevent burning or weakening the metal.

Bend and Secure

Once the conduit is malleable, quickly remove the heat and use heavy gloves to grasp the ends and bend the conduit to the desired angle, applying firm but steady pressure.

Secure the bent conduit in a vise and allow it to cool completely so it sets in position. Avoid quenching the metal with water as this can affect its integrity.

Repeat as Needed

Repeat the heating, bending, and cooling steps for each bend required in the conduit run, reheating adjacent areas to make smoother multi-bend sections.

Use a rag or glove as needed to quickly grasp and reposition the heated area. Take your time and work methodically.

Smooth Edges

Once all bends are completed and cool, use sandpaper or emery cloth to smooth any rough edges or corners. Wipe down the conduit to remove metal dust and particles before installing.

With care and practice, conduit can be bent by hand nearly as precise as with a professional metal bender. Just work slowly, follow proper safety precautions, and be willing to make minor adjustments as you go. The finished product will have a hand-crafted look all its own!