After cutting out the gussets had to clean them up. This includes filing and sanding all the edges smooth especially in the radius between to flange bends. This is a detail where one can be really picky since the radius should be tangent where it meets the straight edge of the flange. Here is a picture of the completed parts:
With a stack of “identical” parts you can see how consistant your flange bending is. There were a couple that were off just a little. I think it happened becasue I had a really small height flange clamped in the bake while the main body was being bent. There isn’t a lot od surface area for the clamping on the little flange. After I added an additional clamp the bending brake it was a little better. That’s my excuse and Dan seemed to buy it…
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