Bent loader crank

[Dj Speed]

Hi I have a bent loader crank which I'd like to straighten then reinforce, it's currently a 30mm square bar, which has bent, and although it's barely a mm shorter than the straight one I'd ideally like to straighten it then weld some 12mm steel plate on either side of both of the cranks to stop them bending again, so first question is what is the best way to straighten bent 30 square bar.
2nd question how do i cut a semi circle each end of the steel plate to mould it around the pin collars? Pin collars are 80mm. Plate is 70mm wide and 12mm thick. Thankyou

 

[Erich]

Straighten with a press. Support crank near ends with V blocks. Mount a dial indicator where the maximum bend is located.
Rotate crank until bend is striaght up. Align High spot with press ram. Push with press, monitor bend with dial indicator. Over bend a little and release, Note how much the crank straightened out. Dial in the overbend so crank is straight when released.

Many ways to cut a semi circle in plate. Depends on the tools you have available and the accuracy you need from the part.

At the low end, Mark circle with pencil in a compass, Cut with Oxy acetylened torch or band saw.

More accurate, mount plate on rotary table on manual mill and cut. Or program CNC mill to cut.

Most accurate, cut with Wire EDM.