Pictures Roller 1, Roller 2 and Roller 3 show progress on my version
of "Ernie's" tubing roller.

Making the first set of dies is a big hurdle finally overcome.  I used 
1.125 thick 6061 aluminum plate as we were donated several tons
of the stuff a few years ago.  I priced the delrin that Ernie used but 
at $110 per foot for six inch diameter I decided that free aluminum would serve the purpose.  We used a Skill saw to cut out 6.5x6.5
squares.  Then we clipped off the corners with the band saw to make rough hexagons.  One of my students suffered a nasty cut
doing this which needed surgery to reconnect tendons.  Ouch! 

The hexagons were then rough turned round on the SB lathes.  

Holding pieces in a Hartford Head on the BOSS 8 B'port the holes were drilled and c'bored.  Tapping was done in the same setup by hand as I don't trust the mill to rigid tap and we don't have a floating tap holder. 

Using our CNC lathe I turned the final diameter to 6.000 and made the radius.  This set of dies is for electrical conduit that measures about .922 OD.

The oilite bronze bushing I bought were 1.752 diameter so I made the bores 1.750 (using the BOSS 8 and milling) and pressed them in using an arbor press.  The dies fit the 1.500 CRS posts very nicely.

My thought is to make dual use dies for smaller diameter stock.  When I get some of these dies made I will post some pictures of them.  And let you know if they worked!