The extension has been progressing great thus far. I profiled the remainder of the extension parimeter to get it finished. Prior to bending I used the belt sander and blended in the the footrest with the extension profile while the metal was still flat.
I then took the footrest half-rounds and using the belt sander again, I did a little more work on the ends of the footrest to kind of radius the ends for asthetics and spent some time deburring and modifying a tap to get the threads a little deeper inside the footrest attach holes.
Next I moved on to making the bend in the extensions. I cut a couple of pieces of scrap aluminum to practice bend prior to doing the real thing. The first practice piece came out ok but I didn't like the radius...it was too large at the bend. I found a scrap piece of steel in my scrounge bin and cut an angle and put a small radius on it. I stuck this in the vise and it gave me more clearance and a smaller radius to put on the bend line. I tried another practice piece and it turned out great. I determined approximately 25 degrees of bend would get me where I needed to be while using the test pieces.
So not it was the real thing. Using my pre-determined methodology I set up the first extension and after making sure it was absolutely where I wanted it to be, I made the BIG BEND! It came out as intended. Set up the next one and bingo....both extensions were bent to perfection.
Next was to put a few lightening holes in the extensions as the rudder pedals have in the top part. I wanted to do these last because I didn't want the bending to be affected by the potentially weakened portion of the extension having the lightening holes. I had to re-mark the hole location and set them up on the machine and punched the 3/4" holes in three locations for each extension.
I spent a little more time doing some fine finishing work to the extensions. The only thing left to do is to countersink the holes in the pedals for the #8 flat head screws that will attach the extensio