Brian: I haven't read all the posts, so I'll probably repeat some of what's already been said. But the best thing you can get for shaping aluminum or any sheet metal is Ron Fournier's book "Metal Fabricator's Handbook". It's loaded with something we all need . . . information. As was said, the mallet and shot bag is what you'll need to shape the part you pictured. But a steel body hammer is needed to smooth it once you hammer it into it's final shape.
Be aware that tools aren't the only thing you have to consider when shaping or welding metals. You must have some knowledge of the alloy with which you'll be working. For instance 3003-H14 aluminum shapes like butter and welds very well, but 6061-T6 shouldn't be bent at all. Be aware, too, that materials such as 3003-H14 work harden, so it must be annealed during the shaping process. Lot's to consider . . . .
Be aware that tools aren't the only thing you have to consider when shaping or welding metals. You must have some knowledge of the alloy with which you'll be working. For instance 3003-H14 aluminum shapes like butter and welds very well, but 6061-T6 shouldn't be bent at all. Be aware, too, that materials such as 3003-H14 work harden, so it must be annealed during the shaping process. Lot's to consider . . . .
Beautiful work!!
