[snip]
The Radiospares 3mm 'bending grade' soft aluminium sheet would bend ok, but with a small amount of crystallisation on the outer of the bend. Trouble is, a thread in soft aluminium would not be very strong. Perhaps consider using self tappers.
Sorry, it depends on the type of aluminium you can get hold of.
Get a strip and try it!
Again, it depends on the type of aluminium. You might have to clamp the ally between two planks on a workbench instead, use hefty clamps.
Depends on the bend radius. 5mm of soft ally, I would guess.
Again, depends on the ally, sorry! Just get some and try it.
Too much. It might be simpler not to use ally. Maybe you have to use fibreglass instead, or thinner stainless or just steel.
Mark K.
Hi,
Try clamping between two bits of thick angle, you may well need to grind the inside edge out a bit on one. Also some blocks of wood to hold them at 45 deg to clamping force IYSWIM:
clamp block angle block clamp
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If there is a local fabricators with a press try taking a sketch along, it might be well worth paying to have it made up.
cheers, Pete.
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