Hey all! First post here... just found this place. Outstanding amount of information. Love it.
Bending the plastic could be done with a heat gun & a makeshift press/brake. You could clamp a straight edge (ie:plywood.. something sturdy): one at the bend line and another a few mm away (at least material thickness to allow bend), and then heat up the plastic in that exposed area. When it gets pliable, bend it & let it cool. I first thought aluminum would be good to clamp as straight edges, but AL is a great heatsink & may hinder heating the plastic a bit. Wood takes a lot more heat than plastic before getting unworkable (ie: burnt), but would also retain more heat than AL which might help with the bend.
