I'm just at the point where I'm experimenting with this product so I'll share what I know.



::I can get a 48"x96"x0.25" piece of Sintra (expanded PVC) from a local plastics shop for $55.



That's a very good price for 1/4"



a) is this material thick enough for that wide of a cage?



It will probably work, but I have no direct experience with PVC cages this large. I understand that boaphile has a steel bar that adds support to all of their 48" cages.



b) 2 options for construction: glue or flanges. which is best?



I'm not terribly impressed with the strength of edge to surface bonds with PVC cement (I've used a few different cement types). But others have done this with great success so I'm sure I've just not mastered it yet.



If I were building a cage I would use a combination of flanges and glue. Or I would order some 3/32" POP Rivets (hard size to find) and rivet the pieces together. I would then use a very thin PVC solvent and inject it along the riveted seam (it would then wick into the joint via capillary action). I've done this with 1/8" rivets and IPS Weld-On 2007 and am very impressed with the strenght of the joint. However, 1/8" rivets are just a bit too big for 1/4" PVC and they bulge the material a bit.



c) heat conductivity? What is SAFEST way to heat? Like top mounted radiant panels but $$$, would a UTH be safe or a heat mat/flexwatt covered and sealed off like a Boaphile?



Not sure, but from the sounds of it these cages need very little heating. However, it sounds like you're going to provide extra ventilation with your top cut-out so you'll have to experiment.



d) toxicity issues? does it need to offgas and will heating cause any kind of vapors or fumes?



Of course it will, but so does almost any other bulding material. Remember that tadpoles of various frog species are reared in sections PVC pipe and do fine. If a tadpole does not die I can't imagine the species you keep will be affected. However, letting cut edges offgas for while is a good idea.

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