silent1313 when you say past 45 deg do you mean under 45 deg(say 42deg)? thats dam tight! thats only 45deg from being flat(180deg) or a duch fold as some call it! with alu if you want to go under 45deg 1.2mm is about the max gage to try to stop cracking,the thicker the alu the more the outside has to strech the tighter you go with the bend.however you might be right and have the wrong type af alu! alu for bending is t2-t3(bend strength) you might have a higher t alu(t4-t5) t6 is more or less billet and would snap.keep going tonton!!