how to bend a 7/8" diameter 1mm wall thickness aluminum pipe?

Question

Hi, I was wondering how to bend a 7/8" diameter 1mm wall thickness aluminum pipe about 55º angle without cracking the wall and having no bumps on the bent area. I'm thinking
A.) through hydraulics but it will crumple the pipe
B.) through heat making the metal soft but I think the wall would crack.
C.) Making a jig to manually bend it but I guess the radius wouldn't be perfect.

Any suggestion or fact will be much appreciated.

Thanks.

Answer 1

to avoid crumpling or cracking fill the pipe with wet sand.you will still need hydraulic or muscle power to bend it and a gig to measure the 55 deg.but it will be a clean bend.

Answer 2

Assuming that that there is some allowable radius for the bend:

Use a Tubing bender. The easiest to find would be the type for bending electrical Conduit. You can find one at a big Hardware store or ask an electrician or wiring installer to bend it for you

Answer 3

Fill it with sand and plug the ends. Then make your bend. The sand will support the pipe so it will not collapse.

Answer 4

hydrolic combined with heat will do it without the crumple, or wrinkle