The box shaped fittings are removed from the PE sheet and cleaned up in the normal way. Removal of the attachment points and sanding to ensure no trace of the stub remains ensures the fit if the bend will be correct
Note: the part bends are not symmetrical, which means all bends should be made in the same order and in the same manner to improve the chance of having identical parts after folding. I’ve tried varying the bend order and for me it always produces dissimilar parts...
![](../../i.imgur.com/MQ5bDIb.jpg)
![](../../i.imgur.com/3apXAU7.jpg)
The best way to ensure part edges remain square to the assembly is a PE folding tool. You can bend PE with pliers and with tweezers 90% of the time and be perfectly fine, but when assemblies have to be bent and be identical, those methods introduce variables which are very hard to control and repeat. In the case of the tweezers, be aware that bending PE with them rounds the edges of the tool and makes picking up and holding delicate parts harder.
![](../../i.imgur.com/aCCeBkt.jpg)
Here the part is bent into the completed shape.
![](../../i.imgur.com/gXfCeQz.jpg)
The part is cleaned with the glass fiber brush, flux is applied lightly and a small flake of solder is placed in the joint.
![](../../i.imgur.com/VtS5zDc.jpg)
Here is the joint after soldering and cleanup with alcohol.
![](../../i.imgur.com/yW4IxNH.jpg)
Here is the main rail the has been cleaned, fluxed, tinned and cleaned with alcohol for installation of the part.
![](../../i.imgur.com/N2I3aJ5.jpg)
The same part after installation.
![](../../i.imgur.com/GM4aNMK.jpg)
The next part is bent an soldered, the rail is repositioned, the install area is prepped and I apply flux to the clean joint. Before proceeding, I install a flat jawed copper heat sink to prevent de soldering the previous joints. The heat sink is rested on a ball of Blu Tack to prevent distortion of the part. When doing this task, I’d highly recommend not using standard alligator clips as the teeth prevent them from being a good heat sink and can damage you PE parts.
![](../../i.imgur.com/3fQeyR8.jpg)
Here is the part after installation and cleanup.
![](../../i.imgur.com/POSJmwz.jpg)
This same process is used for each component added to the rail. Work from one end to the other as much as you can and use heat sinks to protect your previous work. Next installment covers the attachment of the rail hangers.
Cheers