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Would like to make cages for adult corns, pines and maybe a ball python. I can get a 48"x96"x0.25" piece of Sintra (expanded PVC) from a local plastics shop for $55. They will even make the basic box for $60/hr. Initial setup would like to be 5'x2'x1.5' or 4'x2'x1.5' with cutout on top for multifixture hood (flouro and incandescent).
a) is this material thick enough for that wide of a cage?
b) 2 options for construction: glue or flanges. which is best?
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?
d) toxicity issues? does it need to offgas and will heating cause any kind of vapors or fumes?

If anybody has pics of homemade large plastic cages or plans I'd love to see them or just post some links.

I know melamine is easier to work with and has more hardware and trim options but I'd like to avoid the weight issue. If the Sintra is unsuitable, what else is good?

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.

The cages I build are 30x20x20 wdh, and are for my green tree pythons.I havent experimented with any thing bigger but I can stack these four high without any problems whatsoever I would say that if you can get the 1/4 inch material for 55$ asheet that the 1/2 wouldent be that much more expensive and would be better for atleast the front and sides of the cage to support the weight if you plan to stack them

VERY NICE. No way I could build something that nice. Do you have plans or links to plans or would you mind answering questions?

How much to money and time to finish? Glad I won't need mine till next year

Looks like multiple pieces including trim (2" all around?). Is it completely Sintra or are there other materials? With so many seams and edges is it completely glued or is some of it extruded/preformed/heated and bent?

How is it lighted and heated? Light fixture on ceiling hidden by trim?

Doors: glass or acrylic? on track, no lock, floor to ceiling or mounted on trim?

Sorry for all the questions, I'm terribly un-handy and need all the help I can get.
thx