But you would trust your life to a 1" tube bent in a 1.75" die? Obviously not. But if you are going to pack it in sand using the technique in that article might help you out (namely using washed sand and a soft wood slapper). It might also help you bend thin wall 1.75" tubing in your thick wall 1.75" die to do exhaust work.i would never recommend this on anything that might save/ risk your life.
get a 1in die
I would do that if i would use it more than twice. All i need for is to make 2 bends to make a new light bar for my car. It just didnt seem cost effective to buy a die thats only going to be used twice. I have started the light bar and will post some pics after i make the bends.
bringing back this older thread to add a "trick" that was not mentioned
some time ago i needed to make some clean 1.25 bends in a hurry but i had only a 1.5 and 1.75 die.... so i bended a scrap section of 1.5 x .120 DOM , removed the bended tube , split it in half with the plasma, cleaned it up, and bingo; i got myself a dirt cheap 1.25 bender insert .... works perfect for that dimensions that i dont use very often
If you need to, bend a piece of 1.75"x.120" and slice it in half down the center. That will make a sleeve for the die and allow you to bend 1.5" tubing.
To get it down to 1" might be a bit of a challenge....you can either try to bend and sleeve progressively smaller diameters until you get to 1" or you can try to bend heavy wall tubing and do it.
I have done that in the past when I needed to bend something and didn't have the correct die although the easiest thing to do is spend the money and buy the die....you will use it more if you have the proper die.