[pacocap]

I would say that you have to bend it while it is cold.

Yes, that much is clear but first there are other questions to be answered.

[diecutter]

I know even less about bending aluminum than HoFlungDung, but you might try this. Take a test piece of rod and bend it slightly, then heat up the bend area and quench it in water. Bend and quench in steps till you reach your angle.

This may help prevent cracking since most nonferrous metals have work hardening stress removed by quenching which is the exact opposite of how stress is relieved in ferrous metals. Worth a try.

[pacocap]

Take a test piece of rod and bend it slightly, then heat up the bend area and quench it in water. Bend and quench in steps till you reach your angle.

This may help prevent cracking since most nonferrous metals have work hardening stress removed by quenching which is the exact opposite of how stress is relieved in ferrous metals. Worth a try.

OK, assuming that your last assertion is correct, I don't see how bending it cold at first could be a good thing. It would probably be better to heat before even attempting to bend. But if you do, then it is already annealed according to multiple posts and no need to reheat:

http://www.cnczone.com/forums/showpo...66&postcount=8
http://www.cnczone.com/forums/showpo...88&postcount=2
http://www.cnczone.com/forums/showpo...0&postcount=11

Note the differences of opinion about temperatures and whether or not to quench.