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How to Bend Aircraft Aluminum

Be very careful when attempting to bend aircraft aluminum. Aluminum is metal, but it is softer and more brittle than most metals. Heat builds when force is applied to aluminum, and that heat can bend and crack the metal. The key to bending aluminum is to use the proper tools with a steady hand and a certain amount of patience to manage the brake adjustments that must be made.

Things You'll Need

Center punch
Hammer
Tape measure
Sheet metal hand brake
Adjustable wrench

Instructions

- 1
  Determine the location on the metal that needs to be bent. Mark the location on both sides of the aluminum piece using a metal center punch and a hammer.
- 2
  Position the bending leaf of the hand brake in the flat position. Measure the distance between the top clamp lever on the hand brake and the bending leaf using a tape measure. Turn the adjustment bolt on the hand brake with the adjustable wrench to increase the distance to 5/32 inch.
- 3
  Align the punch marks that you made with the front edge of the clamping leaf. Secure the metal in place by pulling the clamping leaf handles downward.
- 4
  Apply pressure to the aluminum by lifting up on the bending leaf.
- 5
  Raise the bending leaf to a point that allows the metal to release.
- 6
  Inspect the metal before using it for any application. Do not use metal with stress cracks or breaks in order to ensure safety.

Aviation