Conversations using plastic card and rod is new to me.
I am just about to begin building a US- SF- Dumvee. To help I am following a recent article by John Tapsell in MIS magazine. To support the adapted roof a roll bar support is required, this is done with 1.6mm diameter rod, bent to the profile of the roof . Whats the best way to bend the rod to a 90 degree angle.


Cookie

Slowly - with round-nose pliers.

Gunnie

Best way is to bend the rod by hand, slowly to just less than 90 degrees. Hold it in that position and bring it near a flame (candle, lighter, etc.) The heat will lock it in the position you have it bent to. Don't hold it too close to or for too long at the flame. With a little practice, it works great.

Good luck.

Instead of using a flame, you might consider using a 100w light bulb. The heat is a little more controllable, worls a bit more slowly and wont burn the plastic if you get too close.

hot water, almost boiling