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Question:

what is the most cost effective way to bend 1'' square aluminum tubing without kinking it?

I bend 7/8 alum tube all the time with great success and with a bender I built myselfHowever recently I had a project that required 1'' square and I kept kinking the stuff and starting overI ended up with about 1 outta 2So if you know a tip or brand name of bender or.Cheapest solution that allows me to acomplish this at my shop gets 10 points.

Answer:

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The square shape is what's making it kinkI don't think you're going to have much luck with any method you useSorry, but bending square stock is not possibleIf it was steel, you could heat it up, but aluminum doesn't give you that optionIf you're looking to make a sharp angle, the best thing you can do is weld 2 pieces together with aluminum welding equipment If you're trying to get a smooth curved angle, I think you're out of luckLet me know if you figure something out because I'd be interested in knowing myselfAnother option you might try is cutting 3 sides, bend the metal and then welding a piece in the place of the openingIt would be a little choppy, but I don't know what else you can do.

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