I have to make lots of little matchboxes and have gone down the casting route and failed. The box and cover fit together perfectly when they leave me but once cast they don't fit at all.

I've decided that the best way forward is to get the inner tray cast and to make the outer sleeve from sheet metal. I've decided to make the sleeve in 2 parts, each with a 90 degree angle and to then solder them together around some sort of former which is the same size as the inner.

Really, my question is in 2 parts -

1. What is the best way to bend the metal? It has to be quick as there will be a lot of them to make. No scoring and filing. I've looked at the Axminster mini brake http://www.axminster.co.uk/sieg-miniature-shear-brake. Does anyone have this or similar?

2. What is the best material to use as a former when I solder the 2 L-shaped pieces together? I was thinking of cutting down fibre board but the stuff I've used in the past is quite soft and crumbly.

Many thanks.