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There are a number of threads on here about building headers, but I have not seen anyone using copper. I got the idea for using a drilled piece of hardwood for a jig from a thread on here. I used the solid copper from some #14AWG house wiring which scales out to 1-9/16” tube in 1/25. It bends nearly as easy as the solder that some have used, but unlike solder….it can be soldered!? Careful bending can avoid most toolmarks on the copper, and minor ones can be sanded off. I think I will head to Michaels and pick up a set of round-nosed jewelry pliers before building my next set. I used a piece of soft wire looped down through another hole and twisted like a tourniquet to get the copper to sit tight together. A slight tapping with a small metal bar or hammer “sets” them and does away with any gaps. Once they are all soldered together, they can be bent up to adjust the angle needed. Then they can be filed to accept a 1/8” O.D. collector.
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