Hello, I have a project where I need some angles on the outside of a box made of ABS plastic, used both as a drain tray for water (there is a bulkhead fitting with a hose for drainage) and access panel. The box wall's are sloped 5 deg. outward from 90, so I need 4x 85 deg. angles with about 1-1/2" legs and 1/2"-3/4" width. The angles will be fastened to the box with machine screws and nuts, and have captive thumbscrews on the other legs for easy removal of the panel.
I would use steel but corrosion may be an issue because of the water and stainless is too expensive for the budget so I wanted to use aluminum.
I know aluminum can fracture/weaken when bent so making the angles from flat stock will probably not work. But if I take a 90deg angle and just bend it 5 deg. will that be ok? The smallest thickness I can find commercially for aluminum angles is 1/16", but a machinist buddy of mine told me I should get thinner if possible like 1/32", but can't find it the places I have looked. Thanks for any input.