[Malcolm T]

As Dave 757 says .
This is what i used and how to.
Items:
1. An oven, I used gas , no experience of electric.
2. Optional, a new cheap stainless large baking tray to fit the oven, for your use only !.
3. Grease proof paper
4. Two planks 1” / 25mm x 20” x 20” ply wood of very flat and blemish free surfaces
5. A flat level table or work surface ( kitchen area is best).
6. A few heavy items , bricks come to mind or breeze block or books.
7. A marker pen permanent
8. A tape ruler
9. Two sheets of A4 paper
10. Masking or sellotape
11. A hack saw or band saw of suitable size and blade medium tpi
12. Plastic heavy duty pipe Pipe is 3.5 - 4mm thick,
13. Oven gloves.
14. A shortish wooden stick 10” inches should do.
15. Some method of holding the pipe firm and steady whilst rotating and cutting with the hacksaw.
16. A mobile phone very important item this !.


Procedures:

1. Overlap slightly the two sheets of A4 paper length ways with the masking or sellotape , wrap around the pipe and level the paper ends to achieve a square 90 degree edge to the pipe side, using marker pen draw a line on the pipe the complete circumference .
Remove marking out paper and cut off the uneven end .
2. Check the throat of the hacksaw can cope with cutting into the centre of the pipe from either end , very important.
3. Use paper again to wrap around and mark out the length of the pipe that is no longer than the length or width of the interior portion of the stainless baking tray , or the flat tray in the oven, hacksaw off.
4. Lay the pipe down on the flat surface and using the marker pen draw a straight line along its length, try and get the pen to centre line height of the pipe by stacking flat items and draw the pen along its length carefully, now cut along the marked line thus with the hacksaw, it should be achievable if the pipe is not too long.
5. Lay a sheet of grease proof paper in the baking tray and place pipe onto it with the cut slit upwards !.
6. Light oven and allow to heat up first , medium setting should do
7. Place the tray in oven and allow to heat the pipe slowly , this takes time !!!.
8. Every few minutes open oven and check on pliability of pipe edges with the wood stick.
9. Keep checking, soon it will be like toffee and the pipe will unroll.
10. Remove from oven quickly, slide the baking paper off the tray with the almost flat plastic onto the ply wood press base. Quickly place another sheet of baking paper on top of plastic and work it down at the edges to allow the upper plywood press part to flatten the plastic out.
11. Place heavy objects bricks , books whatever onto the plywood top press piece, and wait till it cools, 15 to 20 mins should do it.
12. remove top ply wood and inspect for rigidity.
13 The sheet can now be cut on a band saw using a medium / fine TPI blade and treated as sheet material, drilled , screwed, glued.
14. So then i made a 6 volt / 12 volt plastic sheet heater table with nichrome wire for heating the line along the fold like a metal brake,