in practice 3mm acrylic requires more heat than I imagined in order to make the stuff bend through 90 degrees - you can use a wire, but this requires a more complex set up than a simple gun.
The size I chose was one metre square - probably too big - as the heat gun reaches the end of 100 cm. the first bit I suspect has lost too much heat before the nozzle returns.
Anyway, mine requires some refinement yet, and I suspect experimenting with the position of the light source might help to improve the brightness where it's wanted. I've used a modern Energy Saving Halogen bulb rated at 105W, which I was told is the equivalent of the old incandescnent 150W - but not so sure that in practice the light is as bright. However, it's a vast improvement on my old set up, and a big thanks Dirk for all his help and suggestions.
