Once again the factory templates are incorrect for this piece. Overall it was too big and the cutouts for the cyclics were oriented to far to the passenger side. No big deal just make sure that you make the piece out of poster board.
After cutting to the right size it was time to install. I decided to follow the lead of other builders and roll the sheet metal over the seat frame tubing. The first thing I did was anneal the area that I was rolling, this makes it much more malleable. It may be necessary to do this more than once.
After it was in rough position I used the wooden block shown in the third picture along with a large dead blow mallet. I cut the groove in the block using a 1/2" end mill in my Bridgeport. The block is about 8" long. The longer the smoother the rolls. On the far right side of the picture is a slapping spoon. This is useful for spreading the blow and keeping the metal from stretching. Used properly you can shrink the metal with it. The 1/2" rod is used as a dolly with the sheet metal off of the ship.
