bending 1/4" aluminum help

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So I have a good size rectangular hole in the front of my cast aluminum transfer case. I'm going to drop it, prep it, then weld it with my 225 Lincoln precision tig. My question is how would you bend the aluminum to form the hole?? The hole is around a 90 degree corner maybe 2" from the corner on one side and another 2 on the other by maybe 6" in height? Because heating in thinking 6061 aluminum would probly melt and putting in a vice and hammering it would snap it.. So is the only way to cut thin pieces and put a bunch of those together to form it or?? Need help please, and tganks in advance..
Reply:Originally Posted by stroker221So I have a good size rectangular hole in the front of my cast aluminum transfer case. I'm going to drop it, prep it, then weld it with my 225 Lincoln precision tig. My question is how would you bend the aluminum to form the hole?? The hole is around a 90 degree corner maybe 2" from the corner on one side and another 2 on the other by maybe 6" in height? Because heating in thinking 6061 aluminum would probly melt and putting in a vice and hammering it would snap it.. So is the only way to cut thin pieces and put a bunch of those together to form it or?? Need help please, and tganks in advance..
Reply:So then just let it cool to room temp and then I should be able to hammer it to get the bend? Or bend it while hot?
Reply:Originally Posted by stroker221So then just let it cool to room temp and then I should be able to hammer it to get the bend? Or bend it while hot?
Reply:Use 3003Tim Beeker.
Reply:just put in on a gas stove top for 10 minutes work too.
Reply:Originally Posted by AluminumWelderjust put in on a gas stove top for 10 minutes work too.
Reply:Originally Posted by shovelonIf you have an oxy acetylene torch, you could anneal the piece you want to bend. Crack the gas valve and light the flame. Blacken the top side with the soot, then open the oxy valve to get a neutral flame and gently heat the backside. When the black evaporates it will do so around the annealing temp of 6061. When the soot is gone and has cooled at room temp, the piece should be annealed to T-0 for bending.
Reply:Ok well I'll be at our shop and will have an oxy acetalyne torch but not a stove so that'll be what I gotta do. And so cover the bottom with black soot and heat the top until the soot vaporizes on bottom? And are we stuck on 6061 or 3003?
Reply:why not just take 2 pieces and weld them at a 09deg angle?tackleexperts.comwww.necessityjigs.comhttps://www.facebook.com/groups/mach...dingequipment/
Reply:Originally Posted by stroker221Ok well I'll be at our shop and will have an oxy acetalyne torch but not a stove so that'll be what I gotta do. And so cover the bottom with black soot and heat the top until the soot vaporizes on bottom? And are we stuck on 6061 or 3003?
Reply:Ok well it has a good radius around the corner but I could maybe just fill the corner up with weld if I go that way? And ok so 6061-t6, 6061, or 3003. What would be my best bet? Easiest to weld with?
Reply:Originally Posted by stroker221Ok well it has a good radius around the corner but I could maybe just fill the corner up with weld if I go that way? And ok so 6061-t6, 6061, or 3003. What would be my best bet? Easiest to weld with?