Flexible sheet materials to make a curved-end instrument case

<no_spam · 2014-11-08T18:36:11+00:00

I need to make some instrument cases (mandolin, mandola, etcetera) and want to make curved ends - best visual analogy I can think is that the plan view shows a shape like a belt going around a small and large pulley. The problem is what to use for the curved ends. I'm expecting to have to laminate some strips of something around a former but all I can think of to use is aero ply, and that's too expensive. The tightest radius of curvature is going to be about 100mm and the width is going to be about 150mm; I need to be able to attach the curved ends to the (rigid) long sides. What material can the team suggest?