These are a couple of headlight brackets I made up, and the process for bending them. The end had to be a pretty tight bend to get the clamping screws in as close the stanchions as possible so as not to bend the clamps when tightening.
Unfortunately, if you bend non annealed aluminium too tightly the aluminium fractures, so I had to compromise, round the bend a little and sacrifice the mounting bolt position and put up with a small amount of fracture. Aluminium can be hardened after annealing of course, but not quite as easy as steel. Or you can just leave it for 10 years and allow it to harden naturally.
Unfortunately, if you bend non annealed aluminium too tightly the aluminium fractures, so I had to compromise, round the bend a little and sacrifice the mounting bolt position and put up with a small amount of fracture. Aluminium can be hardened after annealing of course, but not quite as easy as steel. Or you can just leave it for 10 years and allow it to harden naturally.
