Bending copper coils is easy when working with (relatively) large coil diamters (in relation to the copper

tube diameter). However, it becomes another story when you try to bend really tight coils.
When making distilling condensers it is important to get as much surface area of tubing into as little as
possible space so as to improve the efficiency of the condenser as well as to save on costs. This requires
the copper to be spiraled in as small as possible diameters.
This short article explain how to bend copper tubing into really tight coils.
The following abbreviations are used:
d = Diameter of copper tube
D = coil diameter into which the copper tube is to be rolled or spiraled.
Copper tubing (or pipe) is normally bought in two conditions:
Soft annealed copper. These are always sold in rolls and this bends the easiest straight from the coil.
This is the copper to use when making spiraled condensers.
Cold drawn copper: These are always sold in straight lengths and is much harder than annealed copper
because it work-hardened during the drawing process. It needs to be annealed (see later how to anneal
copper) before bending otherwise it bends very difficult and tends to collapse or crack easily. Not
recommended for spiraled condensers in distilling equipment without being annealed first.
For large diameter coils: (D > 6 x d):It is quite easy to bend copper tubing when the diameter around which
the copper tube is to be bent is more than 6 times the diameter of the copper tubing.Just roll the copper
tubing around a pipe with suitable diameter by hand. It is easy and the coils will not collapse .Medium
diamter coils (d x 5 < D < 6 x d):For bending diameters between 5 and 6 times the diameter of the copper
tube, commercial tube benders work quite well.
Bending tools or bending springs can be used successfully:-Unfortunately the bending tools are suitable
only for 180 degree (or less) bends only and cannot bend coils as the tool gets in the way of the copper
tubing when making coils. They are also restricted to the fixed diameter of the specific tool.
The bending springs works well but cannot bend into too tight coils. When trying to bend small diameters
with them, the springs can get really DIFFICULT to remove from the copper tube.
How to work with coppa bend:
1. Clean the copper tubing on the inside to eliminate dust and dirt. It can be rinsed with a good
detergent..
2. Plug the one end of the tubing (with something that can withtstand heat of up to 100 degree C) or
crimp the one end of the tubing.
3. Heat and melt the Coppabend in a plastic jug that is suspended in hot (more than 70 degree C) water.
(i.e. like in a bain marie)
4. Hold the tubing at an angle (i.e. 30 degree from horisontal) and pour the molted Coppabend into the
tubing. Do not pour the coppabend vertically into the tube as air bubbles may then be trapped inside
the tube.
5. Now plug or crimp the open end of the tubing as well.
6. Leave the tube tp allow the coppabend to set fully. This may take some time. (i.e. diameters of more

than 12mm let it set overnight)

7. Perform bending around a suitably diameter mandrel - slowly and smoothly.
8. Unplug or uncrimp both ends of the bent copper tube and heat the tube with a hot air gun or hot
water (hotter than 70 degree C) to melt the coppabend.
9. Drain the coppbend into a suitable container for re-use.
10. Rinse the empty tube with water to clean out any coppabend residue. Coppabend is water soluble
and will leave a clear finish.
11. For large diameter copper piping (i.e. larger than 22mm) spiraled into very tight spirals, the
Coppabend can be reinforced with fibre glass or Kevlar (but take care not to use more than 1 gram of
Kevlar to a kilo of Coppabend)