Aluminum tubing material

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Ok Gentelmen here is one for ya. I did a search and I really couldn't find an answer. I also posted on another website and they are helping, but I want to see what you guys think. I have to order a large quantity of aluminum tubing to make out on the cost because I live in Alaska. (shipping kills us) I have this JD 3 bender with 1 inch and 1 and a half inch dies (tubing). I want to build 4 wheeler racks,boat tops, bumpers, and all sorts of cool stuff. I want to use the 1 inch stuff with 1/8th wall and the 1 and 1/2 inch tube with 3/16ths wall. The question is this, which alloy would suit my needs. Here are some suggestions I got from the other site, 6063 T4, 5052 H32, 5086 marine, or 5386. I hope I can even get these right now so what alloy would be best, then second, third,,, you get the idea. Or is there one bettter than these? I dont want to heat it either. Lots to ask, but I know there is alot of expierience out there and I sure would appreciate the help. Thank you.
Reply:6063 T4or 6463 T5, T6 are the more common tubes to bend. Most of the time, they are pipe, not tube. 5052 tube is rare, and when found, not cheap. I have never seen 5086 marine tube. As for 6061 T6, the most common tube of all, it can be bent, but only with wide raduis dies, and what will happen is the outside will flatten unacceptably on you. That stressed tube on the outside will actually take on a plascic look to it, and when flexed, it will crack there. The 6061 will work harden, and crack. Very thick wall, as you explain, with a wide CLR might work okay. I bend aluminum with a JD suared, model 3. I bought Delrin followers from JDsquared to keep the standard alloy followers from galling the aluminum. You will need size specific dies to bend the correct size tube. But, her eis a cheap trick if you get the pipe. For your 1-1/2" die, get some 1-3/8" delrin followers, make sure you get the same CLR. Now, you can bend 1" PIPE, which is a 1-5/16 OD, with the 1-1/2" bender. And you'll get good results. If you try to bend a 1" pipe in a 1-1/4" bender, you'll have either issues, or problems, depending on how lucky you are!!! The aluminum sides will cut in on the main die, and the sidewall will have ugly slices in it. I get my tubing from Morse industries for anodized and mill spec, and Tubing Services in Santa Fe Springs, California for mill spec. They may have size and applications for you, and maybe know a source there in the great white north.And then, after so much work...... you have it in your hand, and you look over to your side...... and the runner has run off. Leaving you holding the prize, wondering when the runner will return.
Reply:Wow thank you Sir, I will definately try the Derlin followers from JD. I guess I will also try some different types of tube and see what works, hopefully I can get some pieces and expeirment. I would think I can get away with some bends on 6061 that arn't so severe like maybe 45s and less. Like some ATV bumpers have a slight bend in them for looks and style and maybe tha tube would work for that. Im sorry about the 45s couldnt help it