Aluminum auto parts are commonly cold formed by stretch forming thin aluminum sections. The forming must be designed so that the part has accurate shape, is free of wrinkles and has minimal distortion of the cross section. The problem has been studied through a combination of experiment and analysis. Rectangular tubes have been formed under controlled conditions in a custom bend-stretch-pressure forming facility. Dedicated nonlinear models of the process have been developed. It is shown that the cross sectional distortion and springback can be estimated by a computationally efficient 2-D model. The efficiency of the model enables quick parametric study of the process from which optimal values of tension and pressure as well as their histories can be established.