Bending Aluminum Tubing?

[Shivang1923]

If you don't have the materials for that way, you could always use all purpose steel from mcmaster carr. Our claw type thing only weighs 16 pounds, which is really a lot less than you'd think because the claw is made up of about 18 ft of steel.

We have contacts at TCNJ and they said that aluminum folds if it isn't bended properly (wont be a problem if you go with dave's idea), but if you're going to use it in a place where it will probably get hit a lot, the aluminum will get damaged. Also, it is expensive to buy an aluminum welder, so if you need to weld, you will be in for a huge problem. (Again, iff you can find one, then go ahead use aluminum, or if you don't NEED to weld, and you can bend it properly, go for it).

Just my thoughts and my experience.

[Laxphan1525]

this isnt a real pretty way but if your good at machining you can cut a slot using a mill at the "correct" angle then bend it by hand and weld the joint to restore rigidity. However if you dont have a mill i have in the past cut a slot using an angle grinder and then welded the joint after. Again neither are that pretty but i have done both in the past and it works. It all depends on what angle you need and how accurate you need to be. Obviously they sell cnc benders and several large companies with access to these benders but most people dont have access to this type of equiupment. like people have said before tube benders work extremely well with aluminum and are an excellent tool for such a process.

[Dad1279]

For the nicest bends, try an canvas awning manufacturer (commercial or nautical) or a race shop that build roll cages. They both will have a 1" die. We have bent tubing with the benders that electricians use, like sold at home depot. If you use the electrical bender, consider using steel electrical conduit for a nicer bend. It is fairly strong, thin wall, inexpensive and not too heavy.

[colin340]

hey kim try freezing it full of ice then bending it that how they bend trumpet parts

[Rob]

Just as an FYI, we have been using bent tubing of various sizes and various bend radii for years, and have never had to heat, cool, or fill it with anything to get good results. The only time you will run into issues is with large tube and tight radii. We have had great success with 1" tubing bent to a radius as small as 3".

The suggestion to find a nautical shop or a race shop that makes roll cages is exactly what you need. The guy who does this for us used to work in a nautical shop, and learned the skills by making roll cages.

You should be ably to use a conduit bender to do what you need providing that you can find one able to accommodate a 1" tube. Using the conduit itself is also a valid option, it is not nearly as heavy as you might expect and makes a god sub for aluminum.

Good luck,

RAZ