Best aluminum alloy for bending?

[Keith_J]

It is impossible to selectively anneal tubing of that size. The best bet to bend it in T0 (dead soft annealed), then if mechanical properties are needed above that, solution heat treat and age for T6.

How would I do this? Make a round bending jig from 1" MDF, using a router bit and pivot arm to precisely route a semicircular channel all around. Route two flat pieces of MDF with channel to grip, then attach both to the bench and go to town. It is best to pivot the jig and fix the flats to the bench, using a lever to pivot the jig

I had to bend several coils from 0.035" wall, 1/4" stainless tube and built a jig like this. Only used a drill press to spin the coils. Nice and tight.

[Showdog75]

Heck,

I'd buy one of the Harbor Freight rollers and get the guys at Swag to make me up a set of dies/rollers before I'd ruin a lot of tube trying to hand bend it.

Be the cheapest solution, but still not the best.

If you want to do this yourself and not out source this is the simplest solution.You will end up with a decent tubing roll for the money as well. I took this advice from Sundown about a year ago on a stainless boat bow rail project and it worked great.Keep us posted on your progress.