Laser cut & bent tube

Hi all,

See attachments (Models are SW2019 SP3). I followed a tutorial on how to model the laser profile ready for hand bending (as per https://www.youtube.com/watch?v=sBmEazh55IE)

When we received samples the mitre joint closes at about 80-85degrees but was supposed to be a right-angle.  Are there any tips or resources people know of for getting these things right on screen?

I plan to remove the locating 'ear' and reduce the outer radius a little bit but any other input would be helpful.

Thanks

Oli