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Re: Bending Aluminum Tubing?
With walls that thin, you will probably also need to reinforce the tubing during the bending process (particularly if you are going to be using a hand bender). The most common way of doing this is to fill the tube with incompressible material to fill the voids. This will prevent the tube from collapsing during the bending process. There are many materials that are suitable for this. The ones most commonly used include low-melting-temperature alloys, sand or even water (if you can completely seal the tube). You can also find special springs that are used to provide the same function (insert them into the tube to the location of the bend, where they support the tubing walls during the bending process).
-dave
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