Started work on the seat. Cut seat to size from a sheet of 0.025" sheet using Andy Snips, then sanded edges carefully to keep it all square and straight.
I cut the holes for the sticks using a fly cutter and hand drill, which was awkward but got the job done and made nice clean holes. The tangent lines between the three circles per side were cut using a Dremel with a metal cutoff wheel, which I have found in the past to make straight. precise cuts. Sand paper and Scotch-Brite pads were used to finish off the holes.
For the hat/seatbelt slot, I drilled all the interior corners with a 1/4" drill bit to get the proper radii on the corners, then cut between them with the Dremel again. It needed quite a bit of cleanup using a dremel sanding head and some files, but it came out very well.
For the seat bends, I didn't really have a brake or other tool that would get it done. So I bent it over the side of my table using a rubber mallet and my hands to get the bends correct, and checked all the angles (88* for the main bend and 11* for the forward bend) with an angle tool to get them correct.
