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Pipe Bending
Seeing Jim's rudder jig jogged my memory to share my experiences with bending 4140N tubing. I have tried several methods but the one that worked for me is both simple and inexpensive.
The tubes around the cockpit area especially the four corner braces around the pilot opening are a little tricky to get the tight radius bends that look good (since they are out in the open and visible).
I made a template of wood much like Jim has done. I welded one end of the tubing closed, filled the tube with sand (silica sand works best because it packs the best but any sand will work- you can even borrow some from your kids sandbox and then return it when you are done) and welded the other end shut. Place the tube in your jig and pull it into shape by hand. This method worked great for the small tubing around the cockpit opening which had compound bends.
Sorry I don't have pictures of this process but it is simple and it works.
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