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Unread 09-09-2013, 04:37 PM   #1
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2001 TJ Wrangler 
Join Date: Oct 2010
Location: Tupelo
Posts: 242
home made flat fenders(aluminum)

Anybody made any flat fenders out of aluminum? I feel pretty comfortable about being able to make them except that I've never bent any aluminum tubing. I'm curious if the JD2 will bend aluminum tubing as well as the mild and chromoly tubing...

Guess I need to call the company up and check before I waist any money on tubing... I'm thinking 1.5"OD x x.120 or .188 thickness

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Unread 09-09-2013, 08:38 PM   #2
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1998 TJ Wrangler 
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It will bend it I used mine to make some rub rails for my aluminum sliders. I've used it at work to make aluminum handrails for stairs also.

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Unread 09-30-2013, 03:07 PM   #3
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The important part about bending aluminum is the temper of the material. The most common aluminum round tube is 6061-t6511. Which is a 60 series alloy with a t6 temper and artificially aged. In a nut shell, it doesn't want to bend. If you anneal it first (heat then quench in water for aluminum). I will bend well but will no longer have the temper which gives aluminum it's strength and rigidity. I've seen some people get away with bending 6061, but I'm sure if you to a microscope to it you would see lots of tears/cracks. 6063-t5 is what tends to be more readily available and can be bent. It IS considered an architectural alloy, but for tube fenders it will be just fine. That's how I made mine and they have held up well. Haven't bounced them off many rocks yet though. The weight savings are awesome, but they will NEVER hold up to rash like steel ones do. Have fun!!! Aluminum is a blast to work with
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Unread 10-02-2013, 02:40 AM   #4
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1991 YJ Wrangler 
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Good info above. I have bent 1.25" sched 40 Aluminum 6061-t6 (speedrail) in my protools bender. Was only doing slight bends and not 90*. The first one went fine. The second bend snapped before I got it very far. I forgot to buff the aluminum clean and the oxidation made it bind in the bender.
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