I think the key is what Stug suggested with two form blocks clamped tightly. You can bend the flange to 90 degrees easily. Just make sure you bend all of it at once. If you start on one side and work your way to the other, it will be wavy. Danny's suggestion of cutting out the corners helps too. I cut mine at 45 degrees. I learned a real trick at a Porterville fly in some years ago. Frank Roncelli, the master rib maker, taught me to use a lead slap as the final step to making the flange lie flat. It is a piece of lead about and inch wide, about 3/8 inch thick and about 1.5 ft long. It actually can shrink the al on the flange. Incidentally, all flanges are 3/4 inch wide. Cubes
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