Source: 2025 Q4 Beartracks, George Huntington
MAKING BENDING DIES TO BEND A RADIUS TO FIT AROUND A TUBE: This trick is great for matching a bend radius to a tube, such as aluminum panels that might be installed under the cabin doors and wrapping around the longerons. First, find a thick tube whose inside diameter matches the outside radius you want.
-use the procedure from the this tip to get a straight line on each side off the tube, then cut the tube in half lengthwise. Clean up the edges and cover them with masking tape, so as not to mark the aluminum sheet when bending.
-now using a tube that fits into the half tube with some clearance for the sheet aluminum you are using, place it into a vise or use “C” clamps to form the sheet aluminum into a nice radius. This works good for the elevator cable attach access at the tail, and the kick panel at the entrance. It also makes a nice large radius like I used for my gear fairings.