How do I bend the 1/16″ thick 2024-T3 aluminum sheet for the fuel valve mounting bracket without cracking it?
First you might consider using a softer type of aluminum (like 5052). Otherwise you need to make sure that the radius of your bend is 3/16″ or greater. Do this by bending it around something with this radius (e.g., sand the radius into a piece of wood, then bend the aluminum around the wood). Also make sure that you make the bend perpendicular to the grain in the aluminum (not parallel to the grain).
