bending aluminum lines

So I need to bend a pair of aluminum lines from an ac evaporator core ninety degrees. How in the bloody hell do I do this without kinkng? Or is there a reason not to?

I use a brake line tool like this one. The dies do a nice job of keeping the line round at tight radii - mine came with them from 1/4" up beyond 5/8".

http://www.northerntool.com/shop/tools/product_200396149_200396149?cm_mmc=Google-pla--Metal%20Fabrication--Pipe%20%2B%20Bar%20Fabrication-_-9094246&ci_src=17588969&ci_sku=9094246&ci_src=17588969&ci_sku=9094246&gclid=CIyeypaGvb4CFShnOgod9Q4Ahg

Never had good luck with the tool above, but have great luck with the sliding shoe type. http://evergreen-rentals.com/index.php?main_page=popup_image&pID=213&zenid=m9p4u03nd4gldvvr6r95ccfgq2

I use the same type of tool that 44Dwarf does.

Also put some oil on the OD of the tube, it makes it a little easier.

Thing to remember is bend radius. Aluminum will deform easily, sometimes kinking/creasing which causes a weak point. Put as large a bend radius as you can for the space. There is a math formula to figure out the bend radius but I don't have it readily available. Just remember that there is one from my time making lines for aircraft. You state AC lines. Diameter? Most of the tools mentioned above are for smaller lines. GRM way is to find a pulley that the tube fits in, preferably the radius your looking for and fab up something that looks like the tools mentioned to keep the bend smooth.

There are bending springs designed to slip over the pipe. Old time plumbers used them to bend copper water pipes. Nobody really does this anymore, but they work great on bending fuel lines, brake lines, power steering lines, etc., but only as long as there isn't a fitting on the end of the tube you are bending. I've had great results using heat to bend larger diameter tubes and pipes. Made a whole exhaust system for the 2002 by putting the exhaust tubing in a vise, heating to cherry red the part I wanted to bend and then gently pushing down on the end of the pipe. Slowly chased the red spot along the pipe and only the red spot would yield and bend. Worked out extremely well even where the tubing went up and over the rear axle.

These work. Anything will bend 3/16 line, some things will bend 1/4, 3/8 or bigger takes a proper tool.

44Dwarf wrote: Never had good luck with the tool above, but have great luck with the sliding shoe type. http://evergreen-rentals.com/index.php?main_page=popup_image&pID=213&zenid=m9p4u03nd4gldvvr6r95ccfgq2