120 Degree Tight Radius Aluminum Bend 2.5in OD

The 120 Degree Tight Radius Aluminum Bend 2.5in OD is engineered for precision fabrication, fluid routing, and custom assembly applications where sharp directional changes are required without excessive material stress. This mandrel-bent aluminum tubing component serves engineers, fabricators, and technicians who demand tight radii in compact spaces—ideal for automotive exhaust systems, hydraulic manifolds, pneumatic lines, and aerospace ducting. The 120-degree geometry combined with the tight 1.75-inch radius allows designers to navigate complex spatial constraints while maintaining structural integrity and flow efficiency.

Constructed from high-grade aluminum and mandrel-bent to specification, this bend features a 2.5-inch outer diameter with 2mm wall thickness and a polished finish that resists oxidation and enhances visual presentation. The mandrel-bend process—using an internal form during bending—ensures the tube maintains consistent wall thickness, prevents collapse, and preserves internal diameter uniformity throughout the curve. With legs measuring 1.5 and 5 inches respectively, the component provides adequate stub lengths for welding, brazing, or threaded coupling integration. The polished aluminum surface not only improves corrosion resistance but also facilitates inspection for defects and simplifies cleaning in food-grade or sanitary applications.

This aluminum bend excels in lightweight assembly environments where steel alternatives would add unnecessary weight—particularly in racing, aircraft, and marine fabrication. Technicians and machinists benefit from the pre-formed geometry that eliminates in-house bending equipment requirements and reduces production lead time. Installation involves standard tube connection methods: welding to compatible aluminum or steel frames, brazing for leak-proof hydraulic lines, or coupling to flanged fittings. The tight 1.75-inch radius and 120-degree angle make this component ideal for engine bay packaging, compact manifold designs, and retrofit applications where space optimization is critical. Weighing just 0.86 pounds, it integrates seamlessly into weight-sensitive systems without compromising durability or performance.