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Any suggestions for what is readily available to fill it (and easily remove)?
Also, ideas for capping the ends so the filler doesn't ooze out?

Marty "have torch, will travel"

Interesting page on that using CerroBend:
http://www.hitechalloys.com/hitechalloys_005.htm
Now, how to cap the ends?
(I know, the best answer is probably drive a couple hours to see some Bloke who would do a much better job if he wasn't too busy buffing sousaphones or beating the orchestra with Thor's hammer)

MartyNeilan wrote: Now, how to cap the ends?

Cut down a cork to fit. No big deal.

Working with lead's no big deal, as long as you're careful where you work, and make sure you get all residue out of the pipe.

I'm still bending tubing the 'Old World' way.... with pitch. It's a bit 'tricky' and quite 'messy' but it works. Make sure the pipe is fully annealed first. Just shove a cork in one end of the tube (usually the smaller end) and heat pitch in a crock pot until it's 'runny' but not smoking. Pour it in the pipe and let it cool fully before bending. The pitch has to be solid to get a descent bend. If the pitch is too soft, the tube will be out of round. It takes a little practice and I'll guarantee you'll screw up a few pipes before you get the knack of it.

Once you have the shape you want (you CAN'T straighten it back out once bent)... just heat the tube up and the pitch will 'drool' out. You can save the pitch for future use. Burn any remaining pitch out of the pipe.

Do those leadpipes with pitch from Allied come pre-annealed?
Yes I say for a starter person Allied filled leadpipe are the way to go.. I have to put a order in to allied in a few days for parts if someone needs a filled pipe give me at call 610-367-7232 I would be glad to help out Thanks Harv.

I am not looking to turn a straight pipe into an elaborate "S" but just to make a few tweaks to an existing pipe - the bends should be fairly minor.

MartyNeilan wrote:I am not looking to turn a straight pipe into an elaborate "S" but just to make a few tweaks to an existing pipe - the bends should be fairly minor.

You'll have to anneal the old pipe first. Fill it with pitch... and then hope the old leadpipe is not suffering from any internal 'rot' that may cause it to split when bent. You also have to be mindful of where the seam is on some leadpipes... especially the older European ones that were basically hand-made.

bloke wrote:I hold 'em in my teeth, heat 'em red hot with an open pit oak fire, and bend 'em with my bare feet.

Bloke always has pictures.....I'm waiting for one of this!

bloke wrote:I hold 'em in my teeth, heat 'em red hot with an open pit oak fire, and bend 'em with my bear feet.

Fixed

TubaTinker wrote: You'll have to anneal the old pipe first. Fill it with pitch...

Where is the best place to get pitch? (for those who aren't card carrying repairmen?)

MartyNeilan wrote:...Where is the best place to get pitch? (for those who aren't card carrying repairmen?)

I originally bought some from Allied. But... after working with dozens of leadpipes that came pre-filled.... I have enough here to allow me to toss flaming balls of pitch over the castle walls if I want. Privately email me your address and I'll send you enough to make a horrible mess in your kitchen! ... gratis.

Marty,Cerrebend, is very easy to use. it liqufies at a very low temp, easiliy done with a small double boiler. Use tapered teflon plugs to plug the ends of the lead pipe.
1) Anneal the leadpipe,
2) find the appropriate sized teflon plugs,
3) heat and liquify the cerrebend
4) Plug one end, add small quantity of oil to lightly coat inside of lead pipe. Discard excess oil.
5) Find an assistant to hold lead-pipe or pour cerrebend.
6) Using a preheated, oiled funnel, pour the liquified cerrebend into the lead pipe holding the bottom plug in place, carefully fill to the top add 2nd plug to seal the leadpipe. It is surprizingly heavy.
7) Carefully rinse/cool lead pipe with cold water to start the cooling and hardening process. Set aside util leadpipe has cooled completely.
Carefully bend to desired design,
9) Using a torch, to reliquify cerrebend and pour back into double boiler, careful, you're just heating it enough to melt the outer edges, it will slide out in chunks back into the bucket. Splashing and making a helluva a mess if not carefl.
10) Clean leadpipe with cleaners and light chem clean.
11) If it spills it is easily picked up and remelted/ cooled into a solid chunk for future reuse.
12) Cerrebend is expensive
13) have fun, have a spare lead pipe, just in case the first go round doesn't go so well.
14)