Bending Aluminum Tubing?

[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