It took me 3 full days and cost about $100 and a donor bike. I have a bit of tidying up to do but its pretty much finished.
Step 1: Getting started.
I had a $20 donor bike and decided to copy the frame geometry. I think its a fairly good bike but its about to cease to exist.
Step 2: Supplies and my Jig
The pine I then cut into +\- 150 mm pieces as the uprights on my jig. I then screwed them to my jig with 2 big screws each and some glue. They have to be fairly strong because thats what the first layer will be clamped to.
The pic below is just a pic of the jig with a mock up bend just to see if I had enough clamps. Wel as it turns out I dont have enough clamps- YOU CAN NEVER HAVE ENOUGH CLAMPS.