Then I cut out some pieces of board slightly oversize to the plans. When you heat this stuff up, it tends to get some irregularities and curving at the edges. So I figure I'll get the curve in there and then cut them to size, square them up on the belt sander, and clean them up. That way I can be sure to cut the piece from the section that has the right curve. I got a big pot of water to a full boil, then I dropped the pieces in one at a time. It only takes 30 seconds or a minute for them to get floppy. Then with some gloves, I put the pieces over the form and shape them down to fit. As soon as it cools, it holds the shape:
Cool, huh? Don't worry. These are oversized on purpose, and they are supposed to have some slightly different shapes for the assemblies that attach on top.
I got to thinking about these after I made them. These are 1/8" thick. There's another piece that double over the tops of these with some cut outs. So that'll be 1'4" thick total. That's too thick and cumbersome, I think. So I found some 3/32" thick stock in my pile in the garage. As soon as I have time, I'll redo this in the thinner stuff. Eventually these will be painted and weathered to look like they are metal underneath.