[Cory]

Originally Posted by Andrew Schuetze

I am open to suggestions and we in fact are very much dependant upon a machine shop to help us with this project. I don't have any experience bending anything other than sheet metal. Does one need a hydraulic bender to make the 90 degree bends in the 5/16" aluminum?

Absolutely. I've never bent anything near that thick, but there's no way you're going to be able to do it with a hand break.