I have finally learned that any deviation from the plans really adds a whole bunch of time to a project! When your designing, drilling, and shaping your own parts you really have to take your time if you want it to come out correctly.
Hopefully all of this time will be well worth it!
Today I created the door doubler. It's 6" x 6" x .032". The hole in the middle is a 3.9" square.
I used a dremell tools with a hard metal cutting bit. It made the job fairly easy, but it still required a whole lot of touchup work. I used a file to straighten the edges and then a dremell sanding drum to finishing out the corners. Finally a little deburring action and we ended up with a door doubler.
