[MrForbes]

Ken was planning on bending solid 6061 rod, not tubing. We bent some 5052 sheet for the robot this year, the old fellow who runs the fab shop suggested stacking two pieces and then bending it, so the lower piece has a much larger bend radius than the corner of the brake....worked great! without the extra piece the relatively mild 5052 cracked noticeably on the outside edge, and it was only .080" thick. We tried bending some 16 gage 6061, the results were not pretty.

Another idea for the solid aluminum rod would be to drill and tap the end of the horizontal piece for a 3/8" bolt, and drill a hole thru the vertical piece and file it flat, so the horizontal piece can seat against it.