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I built Rear Wheel Skirts, and Partial grill blocks with Lexan (polycarbonate). I used a metal bending break, and just bent it like it was a sheet of aluminum. It worked perfect.
Cold bending Lexan (IMHO) is much better than using heat. Heating it is hard to get the temperature even and in the narrow range that allows permanent bending, without bubbling or melting.
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