I would tend to agree on making the die for shaping the copper out of wood or possibly steel. You might also get better results if you can make a pair of 'male and female' molds that you can press the sheet in between rather than just beating it into one with a hammer.
Another thing to consider is that you will probably want a 'reference edge' on the mold that you fasten your part to so that the material in the bend all comes from the other part. This should give you better results than just random bending. (or make the raw peices oversize and trim to fit)
Gooserider
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Designing system, will have Tyan S2468UGN Dual Athlon MOBO, SCSI HDDS, other goodies. Will run LINUX only. Want to have silent running, minimal fans, and water cooled. Probably not OC'c
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