In rereading this post I found this information about HDPE.....
"It seems that some of the plastic sources degrade with time at working temperatures (apparently most plastic that gets professionally recycled is mixed with virgin material to ensure certain specs are met) which I observe as a stiffening while hot and a lowered self-bonding behavior."
This helps me to understand some of the problems I am having with an old Pepsi crate. I think it might be old HDPE!!!