I found a problem with the factory supplied templates for the collective area panels. The Pilots side was fine, but the passenger was too small. Look at the difference in size of the two templates shown in Image 2.
Naturally I did the passenger side first. I was able to use the pilot side template and just make the bends in the other direction and got a good fit.
Like several other builders I decided to wrap the panels around the seat pan area. The first thing I did was anneal the aluminum by blackening with acetelene smoke then burning it off with a hotter flame. This is not for the faint of heart, practice on some scrap before you try it on the real stuff.
The other items are a block of wood with a semi circular groove (shown standing up) I cut the groove with a 1/2" ball end mill in my Bridgeport. The other item is a solid bar same diameter as the tubing. On the far right of the picture is a "slapping spoon". This is used like a hammer but it spreads the blow over a larger area and keeps you from thinning the metal.
If there are any woodworkers out there the bench is a Roubo Style. The holdfast was made by a guy in Alaska and works great. It is holding a backer block. I can slide the panels on the block for riveting or drilling and have good support.
