I use the same method as TBM ..... in my case I use a couple of bits of angle-iron instead of wood and if the piece I'm bending overlaps the vice by much I use G-clamps to make sure the ends stay tight against the aluminium ..... with aluminium I use a bit of 50x100 against the metal and move it along each hit .... going backwards and forwards until the bend is complete ..... ali is soft and it saves the chance of hammer marks. I doubt you'd need more than 1.5mm ali for a tool tray.
K
