[MetalJacket]

What CAD program are you using? With just about any program out there, the sheet metal tools make it really easy to design parts in three dimensions to make sure everything is the size it needs to be and then unfold it later. This prevents you from having to worry about bend deductions and radii during the actual design phase. As for your question about what bend radius to use, that is generally based on the preferences of the shop you plan to work with. Talk to them and see what they prefer, and what they can work with. The default for most CAD programs though is a bend radius equal to the material thickness.