bending alum flat bar

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I need to bend some 1/8" x 1" 6061 T6 at 90 deg. with an inside radius of .375" (easy way).To start with, I used the acetylene soot and propane torch anneal...tried it and it works fine.Then I tried forming the radius using a .75" dia bar, bench vice, and brass hammer. Came out pretty rough.The sketch is my over-engineered solution. Can anyone offer a quicker, easier solution? Otherwise, I'm spending the better part of a weekend building a one-off bender.Thanks Attached Imagesbender.pdf (14.5 KB, 184 views)Miller 211 w/ spool gunMiller Dynasty 200DXLongevity 60i IGBT plasmaO/A w/ crappy chinese torch/gaugesSouth Bend 10K latheGrizzly 4029 10x54 millGrizzly 7x12 hor bandsawangle grnders, bench grnder, bench belt sndr7.5 hp 80gal cmprsor
Reply:Your design looks a lot like my Shop Outfitters compact bender, but simpler. Horror Freight sells a similar bench top unit for a lot less. You might think about simply going and buying one, or at least copying the design a bit closer. The store bought units have a lot more versatility for bending different arcs and even square corner bends with different "dies".http://www.harborfreight.com/bench-t...der-38471.html.No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Originally Posted by DSWYour design looks a lot like my Shop Outfitters compact bender, but simpler. Horror Freight sells a similar bench top unit for a lot less. You might think about simply going and buying one, or at least copying the design a bit closer. The store bought units have a lot more versatility for bending different arcs and even square corner bends with different "dies".http://www.harborfreight.com/bench-t...der-38471.html
Reply:Do you have a shop press? A couple pieces of round bar for your lower die and a piece of plate with a 3/8" round bar tacked to it for your upper anvil.Here's one I found using an arbor press that I like.http://www.diybanter.com/metalworkin...s-bending.html