Recently, at the ExtrusionExtrusion R&D Center of Technical University Berlin (FZS) a tool to extrude a two-chamber hollow profile with single-sided variationsVariations in wall thickness was developed. The tool was tested in an extrusionExtrusion campaign where billets of EN AW 6060 were pressed block on block. The desired wall thickness variationsVariations were achieved, and the profile dimensions were predominantly within the aimed tolerances. However, after extruding a certain number of billets, the tool went into a malfunction leading to several defects inside the tool. Consequently, the tool was undertaken further stress simulationsSimulation to detect the cause of defects. For further characterizationCharacterization of the extruded profiles, specimen of all thick- and thin-walledWall-Thickness sections were taken and tested in tensile tests. Some of these specimens were undertaken an extra heat treatmentHeat treatment prior to the tests to achieve T4 and T6 levels in terms of ultimate tensile strengthTensile strength, yield strength and fractureFracture strain.