If the bar stock is the home store special from the rack (unknown alloy)
AND your bend radius is at least 2x or 3x (1/4" to 3/8"), the bar will
bend easily. For this, the only issue is repeatability of the bend and
control of the bend radius. One of the bench benders
http://www.harborfreight.com/cpi/cta...emnumber=44094
work great (you might need to do a new die, just use a piece of suitable
cold rolled with a hole drilled through the center) You can do almost as
good with a simple plate, some tapped holes, and some 1/2" hardened
steel bolts as bend points.

If you are working with a stiff aluminum like 6061-T6 and a tight bend
radius (less than 2x the thickness), you will be material limited and
will need both good tooling and some what to anneal the material.

rgoldner wrote:
I have to put 35° bends in 1" X 1/8" aluminum. I tried a vice and
hammering the end of the bar that sticks out about 1". This looked
real bad and if I bent the aluminum too much and tried to straiten it
a little it broke. Obviously, I don't have a metal brake. Is there a
better way to do this? I have to make eight bends. I do have a CNC
mill and a lathe as well as tooling and other assorted equipment.

Thanks!