On Sat, 29 Sep 2007 19:58:11 GMT, John Doe
wrote:

Is there an easy way to bend aluminum flat bar? Like a device, either
store-bought or homemade? Something other than a simple vice.

Yes, there are many ways to use bending fixtures on bar stock to
bend it at any radius you desire - if you Google around someplace like
Harbor Freight Tools you'll find several.

But if you don't heat treat and anneal the aluminum bar stock to
"dead soft" condition first before you try bending it I can guarantee
failure, because Aluminum will fatigue and crack at the bend.
Sometimes with a sharp bend you have to anneal it, bend part way,
anneal it again, then finish the bend.

With Aluminum there is very little difference between the heat
needed to anneal and to melt. You'll end up with some "Oopsies" and a
puddle of Aluminum on the floor where you lingered with the torch just
a little bit too long...

Which is why it's usually a whole lot easier and faster to cut your
bar stock with a miter joint, and TIG or MIG (Spool-gun) weld the
pieces together at the angle you want, than to try bending it.
Especially doing it on a production basis.

-- Bruce --