How to Bend Aluminum Pipe

Step-by-Step Guide

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   Step 1: Use a manual pipe bender or a hydraulic bender if you have one.

   You can bend 1 1/4" aluminum conduit by hand, but a manual pipe bender will make it easier.
   
   It doesn't matter what you use to bend the pipe, the main thing is how you keep it from collapsing.
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   Step 2: Fill the pipe with sand or other material

   ,, The pipe will not collapse, but remember that there is a radius to wall thickness / diameter formula that must be observed.
   
   A loose rule of thumb is a maximum 3 1/2" radius to 1" diameter ratio. ,
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   Step 3: and secure three layers of window screening

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   Step 4: with double hose clamps on the ends.

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   Step 5: Bend the pipe slowly so that you can watch to make sure it bends evenly and doesn't collapse or deform

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   Step 6: and watch for cracks that may occur if the pipe is bent too sharply.

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   Step 7: Use whatever means you have to bend the pipe.

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   Step 8: Consider building dies to bend your pipe if you have the equipment

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   Step 9: you can machine your own bending dies for bending the pipe

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    Step 10: or you can rent a manual or hydraulic bender for this purpose.

Detailed Guide

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