I adjusted the opening to 1.338" and it worked perfectly. Instead of rounding the sharp edges of the flat stock that I had used, I sanded the edges with 600 grit sand paper until it was really smooth. Before bending, I greased the flat and the lips.
Now, I'll just have to figure out an easy way to fold the top rails over....
I'll post some pics of my setup when I get some time.
QB, I guess I won't be renting that jig now!
J