Last night I worked to finish up the pad details on the inner structure of the lift gate.... The center one was wider, so I used the same phenolic and just added a wider detail to the opposite side. I missed showing this earlier, but a handy-dandy battery saw works well to remove the bulk of the material, sawing parallel cuts and then just working the saw side to side to clear out the remaining....
Once cut out, the sanding disc is used to cut down the angled sides and touch up the bottom..
This compares the two, showing the difference in width...
Alignment marks transposed from the original, and guide marks indicate the area in need of hammering...
I had a request to show the hammering procedure, so here's another video attempt. The first one is using the phenolic anvil clamped against the work piece in the vise, the second uses 1" square stock as an anvil to clean up the hammer marks a bit...
http://s5.photobucket.com/user/rmcca...eo232.mp4.html
http://s5.photobucket.com/user/rmcca...eo233.mp4.html
...also sounds like I have a loose hammer handle, something for another day....
Then the sanding disc was used for final cleanup. Here's the finished piece, just needs a couple holes drilled....
