Like I said, this is a money venture, I am down to the wire and need to save as much as I can to maintain profits. That's the "why" I have put so much effort into the plastics. PLus I just want to see if I can do it. I will give a cost break down on this build once it sells if you want me to.
I am using a 1500 degree heat gun and soldering Iron kit from Harbor Freight, I go slow and you can see the plastics move around as they become limber, I use clamps and blocks of wood to massage them into shape, keeping an eye on there color, steps are as follows
apply heat, 10-20 sec piece begins to move or loose shape
20-30 sec piece becomes shiny and this is when I place the soldering iron on the joint and remove the heat gun, the iron maintains the heat and I use a cross stitch (welding technique) to blend the two piece, once they are blended, I remove the iron and apply the heat gun again, position the piece in the shape I want it using the blocks or wood and remove the heat gun and let cool, a minute later it is cool and hardened to correct shape.
I flip the piece over and repeat, I add filler as needed ( same color plastic from another bad piece) preheating it with the gun then using the iron to blend them together.
I have not burned any of the plastic, it turns shiny and gets runny long before it burns.