Anyone ever bend thin gauge aluminum without a brake? I have a need to wrap aluminum around a 7' L 4x4, and 2 4' L 2x6's. I have called a few contractors, no one wants to help with such a small project. I was thinking of making my own out of a sheet of plywood and a 2x4.
Problem is, I would like it to look nice as it is being installed on my back porch.
Ideas?

 

Two problems I can see with your idea:
1) 2x4s are slightly rounded. So if you're looking for a clean 90 degree bend, you aren't going to get it without using a sharp edge.
2) I think to get your bend right you have to go slightly past 90 degrees.

I'd check out a HF to see if any of these would work: http://www.harborfreight.com/catalog...?q=metal+brake

Or use a metal edge on your project.

 

I would find some one to let you use a brake IMO.. I went down the same road building my oven and ended up using a friend's buddy's dad's whoever's brake after getting all of my measurements first.

 

Does it have to wrap continuously? What I mean is could you do two sides of the post with one piece and then the other two sides with another piece?

Reason I ask is you can buy pre-bent aluminum flashing for roofing, chimneys, etc... but it is a single bend so you get a "L" not a four sided box.

 

Check your local rental stores. I know the one down the street from me has one to rent.