I realised that the skirt edge isn't the same shape along the full length, so it then became obvious that I will need the skirt flanging tool like the Avery 10490 (currently out of stock). Sometimes you've just gotta have the right tool for the job or the finished product will look awful. The right tool will allow me to roll the front end out while reducing the flange angle as I work further aft.
I turned the rollers out of Acetal (Delrin) and held them in place (0.032" apart) using AN4 bolts threaded into a 10mm steel block. Tomorrow I'll bandsaw the steel to shape and smooth the edges to avoid scratching the ally sheet.
