I'm looking at http://www.qualitywindowscreen.com/store/index.php?main_page=index&cPath=77_80 and the two issues would be how to bent it and how to attach the non-90 deg. angles. Am I on the right track? (no pun intended)
I'm pretty good at figuring out unconventional (i.e. makeshift) methods of getting things done, and this doesn't seem impossible. For joining the pieces of the frame together, plumber's epoxy comes to mind. It's the gray clay-like epoxy you can get in the plumbing section of any hardware or big box store, similar to the gray clay we used to play with in kindergarden.
How to make the bend seems to be the real challenge. We need some sort of jig that will prevent the sides from collapsing, like a conduit bender prevents conduit from kinking while bending it.
Something made from wood comes to mind, but wood might be too soft, especially pine. But what if...
We get a piece of wood the same thickness as the screen framing material, and sandwich it between 2 pieces of flat steel. The steel doesn't have to be real thick, maybe 17 guage, or about the thickness of a street sign. Actually, regular sheet metal for duct work may be thick enough if it has backing.
So now our bending jig consists of a piece of:
- A piece of wood the same thickness as the screen frame material, sandwiched between...
- 2 pieces of sheet metal, which in turn are sandwiched between...
- 2 pieces of 3/4" plywood or 1x6 building lumber.
- All clamped together, leaving us with a slot just barely wide enough to fit the screen frame material into.
Okay, now we have a steel reinforced slot to keep the frame material from kinking as it's being bent. But how to bend it? Oooohhh, I got it. The piece of wood in the middle, the one that is the same thickness as the screen frame material, is curved.
I think we have something here. Let's make a drawing...
So, whaddya think?