Homemade Method for Making Cable Tray Bends

You can create a bend in a homemade cable tray by carefully marking, cutting, and forming the tray using appropriate tools while maintaining structural integrity and safety.

Tools and Materials Needed

Measuring tape and marker or chalk for precise markings Cable tray bender or hand tools (pliers, nose pliers) for forming the bend Bolt cutter or cable cutter for wire mesh trays Hand grinder or file for trimming tray lips Safety gloves and protective equipment Step-by-Step Process for a 90° BendInspect and Clean the Tray: Check for dents, cracks, or defects and clean the tray to remove dirt or moisture for accurate bending. Mark the Bend Area: Measure and mark the exact location and angle of the bend. For a 90° bend, mark the center line and the tray lips that need trimming.

Trim the Tray Lips: Remove the appropriate amount of tray lip (usually half on each side of the center line) using a hand grinder or file to allow the tray to bend without interference. Cut the Center Line (if needed): For metal trays, carefully cut along the center line to facilitate bending, ensuring the tray does not fall open or get damaged. Form the Bend: Use a blunt object or tray bender to gradually bend the tray to the desired angle.

For wire mesh trays, you can bend directly by hand or with pliers. Secure the Bend: Bolt the bent sections together to maintain the angle. For added strength, measure the internal edges and attach a gusset cut from another piece of tray.

Check Alignment and Smooth Edges: Ensure the bend is smooth, the edges are safe, and the tray maintains the correct dimensions for cable installation.

Tips for Safe and Effective Bending

Avoid very sharp bends that can damage cables. Support the bend area to prevent deformation. Maintain the recommended cable bending radius to prevent stress on wires.

For rolling 90° bends, mark slots and sides carefully, then use a tray joiner to align and bolt the sections. By following these steps, you can create professional-quality bends in homemade cable trays, whether for horizontal turns, vertical adjustments, or offsets, without needing expensive pre-fabricated fittings.