Ticon 1.75in Aluminum 6061 45 Degree Mandrel Bend - 1.5D Radius

Precision 6061 Aluminum Mandrel Bend for Custom Intake, Intercooler, and Pipe Fabrication

The TIC301-04526-8150 is a Ticon Industries 1.75 in. outside diameter, 45-degree mandrel bend in T6-tempered 6061 aluminum alloy, bent to a 1.5D radius for smooth, turbulence-minimizing airflow geometry. With a 1.6mm wall thickness, the TIC301-04526-8150 is rigid enough for high-pressure intercooler charge pipe and intake systems while remaining light and weldable with standard ER5356 filler rod. Ticon mandrel bends are machine-bent on controlled tooling to hold consistent OD, prevent wrinkling inside the bend, and maintain a round cross-section through the full 45-degree sweep, unlike crush-bent alternatives that restrict flow and create turbulence at the throat of the bend.

Key Features

• 1.75 in. outside diameter, 45-degree bend angle, 1.5D centerline radius for efficient airflow routing
• 6061-T6 aluminum alloy construction, lightweight and corrosion-resistant with excellent weldability using ER5356 filler rod
• 1.6mm (.063 in.) wall thickness, balancing structural rigidity with weight reduction for performance fabrication
• Mandrel-bent to maintain a round cross-section and smooth inner wall through the full bend arc, preventing flow restriction and turbulence
• Suitable for intercooler charge piping, intake systems, air-to-water intercooler plumbing, and custom cooling or airflow ducting
• Universal fitment, sold as a single bend

Specifications

What's Included

• 1x TIC301-04526-8150 Ticon Industries 1.75 in. 6061 aluminum 45-degree mandrel bend

About Ticon Industries

Ticon Industries is a US-based precision tube bending and fabrication product manufacturer specializing in titanium, stainless steel, and aluminum mandrel bends, straight tubes, and donuts for motorsport, performance, and custom fabrication applications. Ticon products are used in professional racing builds, turbo and exhaust fabrication, and OEM-quality custom plumbing projects worldwide. Their aluminum and titanium product lines are machined and bent to tight dimensional tolerances to ensure consistent fitment and clean weld preparation.

Frequently Asked Questions

The TIC301-04526-8150 has an outside diameter of 1.75 inches. This is the OD of the tube, not the inside diameter. Depending on wall thickness (1.6mm), the inside diameter is approximately 1.624 inches. When coupling to silicone couplers or other tube sections, confirm ID/OD compatibility of all mating components.

The TIC301-04526-8150 is made from 6061-T6 aluminum, the most common structural aluminum alloy used in automotive fabrication. The T6 designation indicates it has been solution heat-treated and artificially aged, providing excellent tensile strength for its weight category and good corrosion resistance without coating.

Ticon recommends ER5356 aluminum filler rod for welding 6061-T6 aluminum tube bends. ER4043 is also commonly used with 6061 but produces a softer weld bead. For intercooler piping and charge pipe applications where weld strength is important, ER5356 is the preferred choice. Clean the weld zone with a dedicated stainless steel brush before welding to remove oxidation.

The 1.5D designation means the centerline radius of the bend is 1.5 times the outside diameter of the tube. For a 1.75 in. tube, this equals a centerline radius of approximately 2.625 inches. A 1.5D radius is considered a medium-tight bend that routes airflow efficiently in confined spaces while minimizing flow separation inside the bend compared to tighter 1D bends.

Yes. The 6061-T6 aluminum alloy and 1.6mm wall thickness of the TIC301-04526-8150 are well-suited for intercooler charge piping on turbocharged and supercharged engines. The mandrel bend maintains a consistent circular cross-section through the 45-degree sweep, preventing the flow restrictions and boost leaks common in crush-bent alternatives.

Yes. The 1.75 in. OD of the TIC301-04526-8150 is a standard dimension for which silicone reducer couplers, straight couplers, and elbow couplers are widely available. Pair with 1.75 in. or appropriately sized silicone couplers and stainless T-bolt clamps for a secure, leak-free intercooler or intake pipe connection.

Yes. Ticon Industries manufactures a complete range of 6061 aluminum tube products including straight sections in 2-foot lengths, 90-degree bends, and 180-degree bends in 1.75 in. and other diameters. These are sold separately and can be combined with the TIC301-04526-8150 to build custom intercooler piping, intake systems, or any plumbing requiring multiple routing sections.

Yes. Ticon Industries produces their aluminum 6061 mandrel bend line in multiple diameters and in 45-degree, 90-degree, and 180-degree bend angles. Part numbers follow a consistent naming convention based on tube diameter and angle. Contact Ticon or your supplier for availability of additional sizes in the same 6061 aluminum product line.

Installation Instructions

1. Dry-fit the TIC301-04526-8150 bend in your piping layout before cutting or welding to confirm the routing angle and leg lengths work within your build constraints.
2. Mark and cut straight tube sections to the required leg lengths using a tubing cutter or chop saw with an aluminum-rated blade.
3. Deburr all cut ends with a file or deburring tool to ensure clean, flush mating surfaces before welding or coupling.
4. Clean all weld zones with a dedicated stainless steel brush and wipe with acetone to remove oxidation and contaminants.
5. Tack-weld the bend to adjacent tube sections in at least three locations before running the full circumferential weld bead.
6. TIG weld using ER5356 filler rod and appropriate amperage for 1.6mm wall aluminum. Back-purge with argon if a full-penetration weld is required.
7. Allow the weld to cool naturally. Do not quench aluminum welds with water.
8. For silicone coupler connections, slide the coupler over the tube end and tighten T-bolt clamps to the coupler manufacturer's torque specification.