When forming an extruded AA6061 aluminum tube, the free surface of the deforming tube becomes rough with increasing plastic strain. This is well known as orange peel phenomenon and has a significant effect not only on the surface quality of a product but also on the forming limit. Therefore in this study, the effect of surface orange peel on the hydroformability of non-heat treated AA6061 extruded tube has been investigated. In an attempt to confirm the surface roughening effect on the forming limit of the tubular specimen, surface asperities generated during the hydroforming process are polished to eliminate the weak positions of the tube which lead to a localized necking. It is also shown that the forming limit of the tube can be considerably improved by changing the chemical composition and extrusion processes.