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Today before heading out to drop Chris at the airport, we worked on
the baggage floor toolbox some more. I laid out and bent up the bottom
and sides of the box.
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Chris helped make this bending block to bend the flanges on the end pieces.
Notice the edges of this block were radiused for a nice 1/8 inch bend radius
and the edge faces were sanded at a 12 degree angle to compensate for the
springback of the material.
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After doing one of four bends in the brake, we bent the other two by clamping
the part to the bend block and bending the flanges over with a mallet.
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They fit great! Thanks for all the help, Chris~
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After getting back from dropping Chris off at the airport, I cut out a section of the
floor panel where the lid will go.
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The lid fits nicely with about 1/32 inch gap all around. Maybe a little less.
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I found a piece of left over piano hinge, cut it to length, and drilled the flanges.
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Some more drilling later and this box is nearly ready to mount. I need to modify
the opening in the floor panel to clear the hinge eyes, do some countersinking and
dimpling, and prime the parts.
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