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Overnight, I realized that the part I bent yesterday needed a flange longer than
1/2 inch. So, I cut and bent another one.
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But, when I matched it up to the angle, it was really obvious the angle wasn't right.
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It turns out that instead of bending to 90 - 28.2 degrees, It just needed to be bent
to 28.2 degrees. Here's the third version. Sigh.
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Here is how the bracket and angled part will mount. Note that I eliminated the
.025 thickness angled part...the angle made that part redundant.
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With the new parts drilled and temporarily mounted to the flap actuator tunnel,
I was able to measure how long the cover needs to be.
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So, the male mold needs to be 11.115 long and 2.298 wide.
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I found an old piece of oak baseboard in my pile of wood. I think this may have come
from back when my aunt and uncle had a house built in the Concord, OH area something like
35 years ago.
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A few passes through the planer had the surfaces cleaned up.
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I cut into a bunch of 12" long sections and glued them up. To keep the layers
from sliding around, I used this little corner jig made of some plywood. It was left over
from when I made a box to hold the gears for my little lathe.
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The garage was getting pretty hot by this time, so I left the glueup to dry overnight.
Note how I flipped every other board over. The original board had a bit of bow to it,
and I thought that alternating these would flatten the bow out.
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