hey gbell, what kind of extrusions are you bending? Window industry? I used to do that. I had some success with filling the extrusion with silicia sand, taping the ends with duct tape. Depends on how tight you are trying to bend them. Also, for some extrusions we had the mill room setup a moulder and run the interior profile in oak. Then the people bending the extrusions would just stick a piece of oak in the opening before bending. Oak stays in, and it also gives you something to screw into.
Hope this helps,
Joe
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