GpsFrontier, just thinking out loud here since this isn't something I have actually tried, but I know some crafters who build molds with plywood and nails and then heat pvc with a heat gun, bending it into the shape of the mold. Perhaps you could use 2x4s to press a round pipe to square it. It would probably take a lot of pressure and I would think the corners would be somewhat rounded. I'm not sure if that would suit your needs, but it might be something to try.
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