2 3/8" long pieces of
hard tubing just large enough to fit over the 8-32 machine bolts
2 pieces of 3M double-sided
foam tape measuring approx 1" square each
3 #4 x 3/8" sheet
metal screws
The first thing you will need to do is save and
print out the shroud template
GIF image. Be sure that you adjust your graphics application's properties so
the calibration line on the template is exactly 6 inches long.
Cut
out the paper template and transfer the shape onto the aluminum flashing material.
In this photo you can see the heavier gauge aluminum template I made for
multiple transfers. This step is not necessary for a single project.
WARNING:
Be very careful when handling the aluminum flashing, it is very sharp and will cut
you before you know what happened.
The aluminum flashing
material is available at most home centers and it is very easy to cut. I used a
plain old pair of scissors which worked very well on the thin material.
Here is the basic shroud after cutting it from
the flashing. I rounded all the inside and outside corners for a more
"finished" look and to help avoid the sharp corners which could be painful.
The template does not reflect the rounded corners but it is an easy modification.
A little touch of sandpaper on the rough edges
and we are ready to continue...
The next step is to add the bend location lines
in the appropriate position on the flashing. The fold lines are indicated on the
template by dashed lines, just transfer them to the same position on your flashing with a
marker. The correct positioning is important so be very careful here.
Though not necessary I used a small sheet metal
bending brake to make the bends in the flashing as indication by the dashed lines.
The sharp edge of a desk or countertop would probably do as well, just make sure to allow
the bends to be slightly sharper than 90 degrees to allow for the "springiness"
of the flashing. Make sure you bend the flashing in the correct direction as
indicated in the photo.
Here is the second and final bend being made in
the flashing. Now the UH X2 shroud has taken shape.
Here is the shroud we just made next to the
completed UH X2 prototype.
