The UPS truck delivered a 5/16" x 12" x 18" piece of 6061 aluminum plate today, that gives me enough to screw up once! As I said earlier, I made a template from the Corvair door, but narrowed it by 2". I got the basic shape cut out a little bit ago, and got the corners smoothed out on the belt sander. Now I need to put it in the mill and mill the top and bottom perfectly flat, then blend the corners into the flats again. Then I need to cut the hole for the latch button. I'll be using an OEM button.
Man, cutting and sanding aluminum makes a mess!
My son laughed at me when he saw me cutting it..... welders hat, goggles, respirator mask, ear muffs, and a long sleeve jacket. But I can safely say I did not inhale any aluminum dust, and there is none in my eyes ears hair, or my arm pits!
I will post up some pics later tonight, it's dinner time!
